Kirby Morgan 37SS Operation And Maintenance Manual

Kirby Morgan® 37SS Diver's Helmet
Operations and Maintenance Manual
KMDSI Part #100-063
Patented, patents pending, foreign patents apply
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Kirby Morgan Dive Systems, Inc.
Santa Maria, CA 93455, USA
Telephone (805) 928-7772, FAX (805) 928-0342
E-Mail: KMDSI@KirbyMorgan.com, Web Site:www.KirbyMorgan.com
Manual prepared by KMDSI, 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
reect 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
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.
© ⅯⅯⅩⅡ 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 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 modications 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.
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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.
II © ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 130318002
Kirby Morgan® 37SS Record Of Changes
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 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 Number Date Description of Change
1 04/28/2010 Updated 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.
2 09/27/2010 Updated warranty information and chapter 1 images.
3 02/07/2011 Updated earphones throughout manual
4 06/14/2011 Changed 61 meters to 67 meters in Appendix 3 Table 3 SuperFlow® 350 Regu-
lator High Pressure Regulated Source
5 10/17/2011 Updated CE Identication Number to 2049 and corrected area code for Santa
Maria Ofce from 850 to 805 in Chapter 2
6 06/14/2012 Updated copyright format
7 03/08/2013 Updated head cushion and added HCFS
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 130318002 III
Record Of Changes Kirby Morgan
B WARNING
Diving with compressed breathing gas is a hazardous activity. Even if you do every­thing right there is always the potential for serious injury or death. No one piece of diving equipment can prevent the possibility that you may be injured or killed any time you enter the water. The information in this manual is intended for users of Kirby Mor­gan helmets and persons that maintain or service Kirby Morgan helmets.
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IV © ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 130318002
Kirby Morgan® 37SS Table Of Contents
Table Of Contents
Warranty Information �������������������������������������������������������������������������������� II Record Of Changes �������������������������������������������������������������������������������� III Denition of Signal Words Used in this Manual ������������������������������������������������� XI
Chapter 1 General Information KMDSI Products ����������������������������������� 1
1.1 Introduction �������������������������������������������������������������������������������������� 1
1.2 Full-Face Masks and Manifolds ���������������������������������������������������������������� 2
1.3 Kirby Morgan Diving Helmets ������������������������������������������������������������������ 4
Chapter 2 Description & Operational Specications Kirby Morgan 37SS ������������������������������������������������������������������������������ 9
2.1 CR Marking �������������������������������������������������������������������������������������� 9
2.2 CE Certication ���������������������������������������������������������������������������������� 9
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�4�1 SuperFlow® 350 Demand Regulators ������������������������������������������������������� 10 2�4�2 Minimum Operating Temperature ����������������������������������������������������������� 10
2.5 Cage Code �������������������������������������������������������������������������������������� 10
2.6 Operational Specications & Limitations ���������������������������������������������������� 10
2�6�1 Using a High-Pressure Breathing Gas Supply �����������������������������������������������11
2.7 Helmet Features ��������������������������������������������������������������������������������12
2.8 General Description ���������������������������������������������������������������������������� 16
2�8�1 Helmet Shell �������������������������������������������������������������������������������� 16 2�8�2 Gas Flow Systems �������������������������������������������������������������������������� 16 2�8�3 Emergency Gas Supply System (EGS) ������������������������������������������������������18 2�8�4 Helmet Attachment to the Diver ������������������������������������������������������������� 19 2�8�5 Sealing Arrangement ����������������������������������������������������������������������� 21 2�8�6 Reducing Carbon Dioxide ������������������������������������������������������������������ 21 2�8�7 Communications ���������������������������������������������������������������������������� 21 2�8�8 Equalizing the Middle Ear ������������������������������������������������������������������� 21 2�8�9 Face Port or Viewing Lens ������������������������������������������������������������������ 22
2.9 Accessories ������������������������������������������������������������������������������������� 22
2�9�1 Eye Protection for Welding ������������������������������������������������������������������ 22 2�9�2 Special Regulator Tools for SuperFlow® 350 ������������������������������������������������ 22
2.10 Helmet Transport And Storage �������������������������������������������������������������� 23
2�10�1 Helmet Carrying Bag ���������������������������������������������������������������������� 24
2.11 Use of Kirby Morgan Original Replacement Parts ����������������������������������������� 24
Chapter 3 Operating Instructions �������������������������������������������������������� 25
3.1 Introduction �������������������������������������������������������������������������������������25
3.2 Design Purpose ��������������������������������������������������������������������������������� 25
3.3 First Use of Your Kirby Morgan Diving Helmet ���������������������������������������������� 26
3.4 Initial Adjustments to Your Helmet ������������������������������������������������������������ 26
3�4�1 Head Cushion ������������������������������������������������������������������������������ 26
3.4.1.1 Head Cushion Removal ������������������������������������������������������������������� 27
3.4.1.2 Clean and Inspect ������������������������������������������������������������������������ 27
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 130318002 V
Table Of Contents Kirby Morgan
3.4.1.3 Stufng ����������������������������������������������������������������������������������27
3.4.1.4 Head Cushion Adjustment ����������������������������������������������������������������� 27
3.4.1.5 Foam Trimming tips ����������������������������������������������������������������������� 27
3.4.1.6 Foam Stufng Tips ������������������������������������������������������������������������ 27
3.4.1.7 Adding Earphone Holes to the Head Cushion ������������������������������������������������ 28
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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 Stufng 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�5�1 Pre-Dive Visual Inspection ������������������������������������������������������������������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
3.10 Diving Procedures ����������������������������������������������������������������������������48
3�10�1 Standing By to Dive ����������������������������������������������������������������������� 48 3�10�2 Attaching the Umbilical to the Harness ���������������������������������������������������� 49 3�10�3 Diver Dons Helmet ������������������������������������������������������������������������ 49 3�10�4 Diver Check Gas Flow Systems ����������������������������������������������������������� 49 3�10�5 Communications Check ������������������������������������������������������������������� 49 3�10�6 Diver Ready ������������������������������������������������������������������������������� 49 3�10�7 Water Entry and Descent ������������������������������������������������������������������49
3.11 Emergency Procedures ����������������������������������������������������������������������49
3�11�1 Flooding ����������������������������������������������������������������������������������� 49 3�11�2 Inhalation Resistance ���������������������������������������������������������������������� 50 3�11�3 Gas Flow Stops ��������������������������������������������������������������������������� 50 3�11�4 Demand Regulator Free Flow ��������������������������������������������������������������50
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
Chapter 4 Troubleshooting ������������������������������������������������������������������ 53
VI © ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 130318002
Kirby Morgan® 37SS Table Of Contents
4.1 General ������������������������������������������������������������������������������������������ 53
4.2 Communication Malfunction ������������������������������������������������������������������ 53
4.3 One Way Valve Malfunction ������������������������������������������������������������������� 53
4.4 Side Valve Malfunction �������������������������������������������������������������������������54
4.5 Water Leakage Into Helmet �������������������������������������������������������������������54
4.6 Demand Regulator Malfunction ��������������������������������������������������������������� 55
4.7 Emergency Gas Supply Valve �����������������������������������������������������������������55
Chapter 5 Inspection and Maintenance ����������������������������������������������� 57
5.1 Routine Maintenance �������������������������������������������������������������������������� 57
5�1�1 Daily Pre-Dive Maintenance A2�3 �����������������������������������������������������������57 5�1�2 Daily Post Dive Maintenance A2�6 ���������������������������������������������������������� 57 5�1�3 Supervisors Equipment Checks A2�4 and A2�5 ��������������������������������������������� 57
5.2 Monthly Maintenance �������������������������������������������������������������������������� 57
5.3 Yearly Maintenance ���������������������������������������������������������������������������� 57
5�3�1 Overhaul/Inspection Checklist A2�1 ��������������������������������������������������������� 57
Chapter 6 General Preventative Maintenance �������������������������������������59
6.1 Introduction �������������������������������������������������������������������������������������59
6.2 Required tools, Sealing, Cleaning Agents, Lubrication �������������������������������������59
6�2�1 Component and Parts Cleaning ������������������������������������������������������������� 59 6�2�2 Component and Parts Lubrication ���������������������������������������������������������� 60 6�2�3 Teon® Tape �������������������������������������������������������������������������������� 60 6�2�4 RTV Sealant ��������������������������������������������������������������������������������60 6�2�5 Thread Locker ������������������������������������������������������������������������������60
6.3 General Cleaning & Inspection Procedures ��������������������������������������������������61
6�3�1 O-Ring Removal/Inspection/Cleaning and Lubrication �������������������������������������� 62 6�3�2 General Cleaning Guidelines ��������������������������������������������������������������� 62
6.3.2.1 Mild Soap Solution for General Cleaning and Leak Detector Use ������������������������������� 63
6.3.2.2 Acidic Cleaning Solution and Procedures ����������������������������������������������������64
6.3.2.3 Germicidal Cleaning Solutions and Procedure ������������������������������������������������64
6.4 Daily Maintenance ����������������������������������������������������������������������������� 65
6.5 Monthly Maintenance (or between jobs) (See Dive Lab Checklist A2.2) ������������������ 67
6�5�1 Locking Collar Assembly & Helmet Ring ��������������������������������������������������� 67 6�5�2 Neck Dam Ring Assembly ������������������������������������������������������������������ 67 6�5�3 Head Cushion and Chin Cushion ����������������������������������������������������������� 67 6�5�4 Communications Inspection ����������������������������������������������������������������68 6�5�5 Lubricate Nose Block O-rings �������������������������������������������������������������� 68
6.6 SuperFlow® 350 Regulator & Exhaust System Post Dive Cleaning & Sanitizing ��������� 68
6�6�1 Post Dive Disassembly ��������������������������������������������������������������������� 68 6�6�2 Sanitizing ����������������������������������������������������������������������������������� 70 6�6�3 Post Dive Reassembly ���������������������������������������������������������������������� 71
Chapter 7 Breathing System Maintenance and Repairs �����������������������73
7.1 Introduction �������������������������������������������������������������������������������������73
7.2 Torque Values ����������������������������������������������������������������������������������� 73
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
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 130318002 VII
Table Of Contents Kirby Morgan
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
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7.5 Defogger Valve ���������������������������������������������������������������������������������79
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 SuperFlow® 350 Demand Regulator ���������������������������������������������������������� 91
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
7.10 SuperFlow® 350 Regulator Disassembly ��������������������������������������������������� 98
7.11 Inspection of SuperFlow® 350 Demand Regulator Parts ���������������������������������� 99
7.12 Cleaning SuperFlow® 350 Regulator Parts ����������������������������������������������� 101
7�12�1 Precautions for Cleaning ���������������������������������������������������������������� 101 7�12�2 Cleaning Instructions �������������������������������������������������������������������� 101
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
KMDSI Tool Kit) ��������������������������������������������������������������������������������� 108
7.14 Oral/Nasal Mask ���������������������������������������������������������������������������� 110
7�14�1 Oral/Nasal Removal ��������������������������������������������������������������������� 110 7�14�2 Inspection of Oral/Nasal ����������������������������������������������������������������� 111 7�14�3 Oral/Nasal Replacement ����������������������������������������������������������������� 112
7.15 Reinstalling the Pod on the Helmet ������������������������������������������������������� 112
7.16 Reinstalling the Regulator on the Helmet ������������������������������������������������� 114
7.17 Overpressure Relief / Bleed Valve Overhaul Procedures �������������������������������� 116
7�17�1 Overpressure Relief Valve ��������������������������������������������������������������� 116 7�17�2 Overpressure Relief Valve Disassembly and Cleaning ����������������������������������� 117 7�17�3 Overpressure Relief Valve Reassembly �������������������������������������������������� 117 7�17�4 Overpressure Relief Valve Lift Check/Setting �������������������������������������������� 117
Chapter 8 Mechanical System Maintenance �������������������������������������� 121
8.1 General ���������������������������������������������������������������������������������������� 121
VIII © ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 130318002
Kirby Morgan® 37SS Table Of Contents
8.2 Helmet Shell Inspection���������������������������������������������������������������������� 121
8.3 Nose Block Assembly ������������������������������������������������������������������������ 121
8�3�1 Nose Block Assembly Removal ����������������������������������������������������������� 121 8�3�2 Nose Block Device Replacement ��������������������������������������������������������� 122
8.4 Handle ����������������������������������������������������������������������������������������� 123
8�4�1 Handle Removal ������������������������������������������������������������������������� 123 8�4�2 Handle Grip Rubber ���������������������������������������������������������������������� 124
8.4.2.1 Handle Grip Rubber Removal ������������������������������������������������������������ 125
8.4.2.2 Handle Grip Rubber Replacement �������������������������������������������������������� 125
8�4�3 Handle Replacement ��������������������������������������������������������������������� 125
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�8�1 Snap Tab Removal ������������������������������������������������������������������������ 136 8�8�2 Snap Tab Replacement ������������������������������������������������������������������� 136 8�8�3 Chin Strap Removal ���������������������������������������������������������������������� 136 8�8�4 Chin Strap Replacement ������������������������������������������������������������������ 136
8.9 O-ring Seal Replacement ������������������������������������������������������������������� 138
8.10 Helmet Ring ��������������������������������������������������������������������������������� 138
8�10�1 Helmet Ring Repairs ��������������������������������������������������������������������� 138
8.11 Sealed Pull Pins ����������������������������������������������������������������������������� 138
8�11�1 Removal of Sealed Pull Pins ������������������������������������������������������������� 138 8�11�2 Replacement of Sealed Pull Pins �������������������������������������������������������� 139
8.12 Swing Tongue Catch ����������������������������������������������������������������������� 139
8�12�1 Disassembly of the Swing Tongue Catch ������������������������������������������������ 140 8�12�2 Reassembly of the Swing Tongue Catch ������������������������������������������������� 141
8.13 Locking Collar ������������������������������������������������������������������������������� 142
8�13�1 Locking Collar Removal ����������������������������������������������������������������� 142 8�13�2 Locking Collar Disassembly ������������������������������������������������������������� 143 8�13�3 Locking Collar Reassembly �������������������������������������������������������������� 144
8.14 Head Cushion (pre October 2012) ��������������������������������������������������������� 145
8�14�1 Head Cushion Foam ��������������������������������������������������������������������� 145 8�14�2 Chin Cushion ���������������������������������������������������������������������������� 146 8�14�3 Chin Cushion Foam ��������������������������������������������������������������������� 146
8.15 Communications System ������������������������������������������������������������������� 147
8�15�1 General ���������������������������������������������������������������������������������� 147 8�15�2 Earphone Inspection �������������������������������������������������������������������� 147
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 130318002 IX
Table Of Contents Kirby Morgan
8�15�3 Removal of Communications Assembly ������������������������������������������������� 148 8�15�4 Replacement of Communications Assembly ��������������������������������������������� 149 8�15�5 Microphone Replacement ��������������������������������������������������������������� 149 8�15�6 Earphone And Wire Assembly Replacement ��������������������������������������������� 150 8�15�7 Waterproof Connector ������������������������������������������������������������������� 150
8.15.7.1 Connector Removal �������������������������������������������������������������������� 150
8.15.7.2 Connector Replacement ���������������������������������������������������������������� 151
8�15�8 8 Terminal Connections in the Waterproof Connector������������������������������������ 151 8�15�9 Communications Posts ����������������������������������������������������������������� 153
8.15.9.1 Communications Post Removal ��������������������������������������������������������� 153
8.15.9.2 Communications Post Replacement ����������������������������������������������������� 153
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37SS
Chapter 9 Accessories for the Kirby Morgan 37SS ���������������������������� 155
9.1 Introduction ����������������������������������������������������������������������������������� 155
9.2 Low Pressure Inator Hose ������������������������������������������������������������������ 155
9�2�1 Installation of the Low Pressure Inator Hose ��������������������������������������������� 155
9.3 Weld Lens Assembly ������������������������������������������������������������������������� 155
9�3�1 Weld Lens Assembly Installation ���������������������������������������������������������� 155
9.4 Weld Shield Assembly ����������������������������������������������������������������������� 156
9�4�1 Weld Shield Assembly Installation �������������������������������������������������������� 156
9.5 Use of Quick Disconnect �������������������������������������������������������������������� 156
9.6 Weld Shield Assembly ����������������������������������������������������������������������� 157
9�6�1 Weld Shield Assembly Installation �������������������������������������������������������� 157
9.7 Use of Quick Disconnect �������������������������������������������������������������������� 157
Table of Equivalents �������������������������������������������������������������������������� 159 Appendix 1 Torque Specications ����������������������������������������������������� 160
Checklist, Maintenance, and Pre-Dive Inspections ������������������������������������������� 161
Appendix A2 Maintenance and Inspection Procedures ���������������������� 162 Appendix 3 Supply Pressure Requirements & Tables ������������������������� 164
Appendix 3 Table 1 Work Rate Expressed as Respiratory Minute Volume (RMV)* ��������� 165 Appendix 3 Table 2 Compressor Supply Table SuperFlow® 350 ����������������������������� 165 Appendix 3 Table 3 SuperFlow® 350 Regulator High Pressure Regulated Source ��������� 167
Appendix 4 Standard Kirby Morgan Surface Supply Pressure Formula ­Old Method ��������������������������������������������������������������������������������������� 167
X © ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 130318002
Kirby Morgan® 37SS Denition of Signal Words Used in this Manual
Denition of Signal Words Used in this Manual
For your protection, pay particular attention to items identied by signal words in this manual. These terms are identied 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 difculty 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, specications, models and availability. Since some information may have been updated since
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 130318002 XI
B WARNING
Denition 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
XII © ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 130318002
Kirby Morgan® 37SS Denition 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 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.
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 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.
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.
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 130318002 XIII
Denition 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 specic 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. certication programs, they must only be used with C.E. certied components. Diving operations should only be conducted within the limits of the operational specications, and in accordance with the rules and regulations established by the governing authority in the specic 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.
XIV © ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 130318002
Kirby Morgan® 37SS Chapter 1 - Introduction
STOP!
BEFORE GOING FURTHER-
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, scientic, 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.
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 130318002 1
Chapter 1 - Full-Face Masks and Manifolds Kirby Morgan
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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.
Both the 18 and 28 are approved.
2 © ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 130318002
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 congurations 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.
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 130318002 3
SuperMask M-48
w/ Rebreather pod
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, scientic 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.
SuperLite® 17A/B
approved and ™ marked approved and ™ marked
Yoke and Latch Catch
Assembly
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Kirby Morgan® 37
Neck Pad and
Sealed Pull Pins.
4 © ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 130318002
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, efcient 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” conguration 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.
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 130318002 5
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 specically designed for surface-supplied diving, that will per­form over the wide range of pressures delivered by low pressure compressors. An ordinary scuba regu­lator mounted on a diving helmet is not capable of delivering the 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 renishing 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.
6 © ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 130318002
• 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, efcient maintenance of the helmet's com­munications.
The advantages of this stainless steel helmet include the following:
• Rugged helmet shell and other components
• No renishing required if the surface is scratched or gouged
• Elimination of threaded inserts for securing port retainer to helmet shell
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 130318002 7
Kirby Morgan® 37SS Chapter 2 - CR Marking
-
0477
Chapter 2
Description & Operational Specications 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 specications. 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 certicates 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 afxed.
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.
Category of PPE: III
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 130318002 9
CE Mark
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. Helmet model;
4. the year of production;
5. CE marking: ;
6. number of notied body.
Chapter 2 - Product Specications Kirby 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 Eurons-Modulo Uno S.p.A.
Address: Via Cuorgne, 21-10156 Torino, ITALY
Identication 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 specic 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@
10 © ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 130318002
2.5 Cage Code
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.
Kirby Morgan® 37SS Chapter 2 - Operational Specications & Limitations
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 scientic 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 sufcient 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.
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 130318002 11
Chapter 2 - Helmet Features Kirby Morgan
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 specications. The use of unregulated gas sources is extremely dangerous.
The use of standard SCUBA type regulators is unacceptable, as there are no provisions for adjusting the in­termediate pressure to the diver. Only proven systems that allow for varying the gas supply pressure to the diver should be used for umbilical diving.
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 rene 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, efcient 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:
• the face port
• communications components
• the oral/nasal mask (No KM47 / KM77)
• the nose block device (No SL27)
• the head cushion (SL27, 37, 47 & 57)
• neck ring & neck dam (SL27, 37, 47 & 57)
• helmet shell (KM77 only)
®
37SS
12 © ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 130318002
Kirby Morgan® 37SS Chapter 2 - Helmet Features
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)
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 130318002 13
Chapter 2 - Helmet Features Kirby Morgan
KEY FEATURES OF THE KM 37SS
®
37SS
Steady Flow Valve provides an ad-
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
actually clears the diver’s shoulders.
14 © ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 130318002
Modular Communications System
can be either bare wire posts as shown or a waterproof connector. The waterproof type is recommended when a “round robin” or diver/tender both mics “on” communications system is used.
SuperFlow® Regulator
This all metal, fully adjustable, Commer­cial Rated™ demand regulator provides easy breathing and excellent performance with low pressure compressors
Kirby Morgan® 37SS Chapter 2 - Helmet Features
Adjustable Neck Pad
Helps provide for a cus­tomized t
Neck Dam Sealing Surface
Helps to provide a positive seal.
Chin Strap
Helps to adjust the t of the helmet
Serial Number location
Head Cushion
Conforms to the diver’s head.
Sealed Pull Pin
Part of the latching system.
Wings Exhaust System
Ultra low-resistance exhalation system. Very dry.
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 130318002 15
Low Pressure Port
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 simplies getting out of the helmet.
Chapter 2 - General Description Kirby 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)
Retaining Pin
Clamp
16 © ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 130318002
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