Kirby Morgan 47 Operation And Maintenance Manual

WARNING

Kirby Morgan 47 Helmet

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Operations and Maintenance Manual

KMDSI Part #100-070

Patented, Foreign Patents Pending, other patents apply.

Kirby Morgan Dive Systems, Inc.

1430 Jason Way

Santa Maria, CA 93455, USA

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

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

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

NOTE: This manual is the most current for the Kirby Morgan 47 Helmet. It is page dated June 2012. 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.

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 47 helmet meets or exceeds all performance and testing requirements of all government and non-government testing agencies throughout the world. They are CE approved. It is approved for use on all commercial and military work underwater.

Kirby Morgan, SuperLite®, BandMask, Band Mask, KMB, KMB-Band Mask, DSI, Diving Systems International, EXO, REX®, SuperFlow® and DECA are all registered trademarks of Kirby Morgan Dive Systems, Inc. Use of these terms to describe products

that are not manufactured by KMDSI is illegal.

The two dimensional images (such as photographs and illustrations) of our products are © copyrighted and trademarks of Kirby Morgan Dive Systems, Inc. The three dimensional forms of our products are trademark, trade design and trade dress protected.

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 120614002

Kirby Morgan® 47

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 head cushions. In addition, due to the electrolytic nature of underwater cutting and welding, chrome plating cannot be warranted when the diver engages in these activities.

Should any part become defective, contact the nearest authorized KMDSI dealer. If there is no dealer in your area, contact KMDSI directly at (805) 928-7772. 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.

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.

Kirby Morgan® 47

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.

Change Number Date Description of Change

1 08/20/2008 Added: CE approval text to page 23 in chapter 2.

2 09/30/2008 Removed page number column on page number III.

Renumbered chapter 6 pages and subsequent chapters in table of contents.

®

REX

3 changed to REX® and image updated on page 14.

Added CE Certication text and logos on pages 19, 21 and 22.

Tables updated and moved to back on pages 23 and 24. Renumbered Chapter 2 Sections Image Updated page 28.

Updated Exploded view of REX® regulator on page 29.

Rearranged chapter 5 into 2 columns, pages 63. Updated Image of special tools on page 64.

Updated text in chapter 6, 6.2.2 on page 65. Updated Exploded view of REX® Exhaust System and changed REX® 3 to REX®

on page 73. Replaced Whisker Clamps with Tie Wraps on pages 74-76. Rearranged and updated Chapter 7, 7.8.1, 7.10 on page’s 92-96. and page’s 101-104, and 106-107.

Rearranged Appendix 1: Torque Specications on page 145-146. Added Appendix A2 on page 143. Added Appendix 3 on page 145.

3 11/05/2008 Added D-Ring to Image on page 18.

Blowapart Image Updated with D-Ring on page 32, 38, and 123.

Text Updated on pages 61-62. Text Updated on page 120.

Added Microphone Diagram on page 134. Image Updated on page 135.

Appendix A1: Torque Specications updated on page 141.

4 2/19/2009 Page 131 8.15.3 Removal of Communications Assembly added communications

breakage text.

Page 131 8.15.4 Replacement of Communications Assembly added communications breakage warning.

Kirby Morgan® 47

WARNING

5 3/30/2009 Page 74 Section 7.3.2 Step 3: Changed Picture caption, 270 kg. cm to 17 Newton

6 11/06/2009 Chapter 2 Addition of CE Conforming Criteria.

7 08/19/2010 Updated knob images and diagrams.

8 04/11/2011 Updated earphones throughout manual

9 06/17/2011 Changed 61 meters to 67 meters in Appendix 3 Table 3 Topside High-Pressure

10 10/17/2011 Updated CE Identication Number to 2049 and corrected area code for Santa

11 06/14/2012 Updated copyright format

Meters. Page 79 Section 7.4.4 Step 3 and 6: Changed 50 inch pounds to 35, 5.65 Newton Meters to 4 and 40 inch pounds to 15. Page 109 Section 8.4.2 Step 4: Changed 35 inch pounds to 20. Page 118 Section 8.6.2 Step 14 and 16: Changed picture caption 16 kg.cm to 1.5 Newton Meters. Page 120 Section 8.6.3 Step 9: Changed 16 kg. cm to 1.5 Newton Meters. Page 123 Section 8.11.2 Step 3: Changed 35 inch pounds to 12 and 39 kg.cm to

1.3 Newton Meters. Page 125 Section 35 inch pounds to 20 and 27 kg.cm to 2.25 Newton Meters.

Page 139 Torque Specications: Updated location numbers and added part # 555-

167 Bent Tube Assembly.

Regulator Settings for use with the Kirby Morgan REX® Regulator

Maria Ofce from 850 to 805 in Chapter 2

Diving with compressed breathing gas is a hazardous activity. Even if you do everything right there is always the potential for serious injury or death. No one piece of diving equipment can prevent the possibility that you may be injured or killed any time you enter the water. We do not herein make any effort to teach the principles of diving. The information in this manual is intended for users of Kirby Morgan helmets and persons that maintain or service Kirby Morgan helmets.

Kirby Morgan® 47

Table Of Contents

Warranty Information �� II Record Of Changes Denition of Signal Words Used in this Manual

Chapter 1 General Information KMDSI Products �� 1

1.1 Introduction

1.2 Full-Face Masks and Manifolds

1.3 Kirby Morgan Diving Helmets

Chapter 2 Description & Operational Specications Kirby Morgan 47 �� 9

2.1 CR Marking

2.2 CE Certication

2�2�1� CE Marking �� 9

2�2�2� Notied Body �� 10

2.3 Other Marking �� 10

2.4 Product Specications ��10

2.5 Regulator Performance �� 10

2�5�1 REX® Regulator �� 10

2�5�2 Minimum Operating Temperature ��10

2.6 Cage Code �� 10

2.7 Operational Specications & �� 10

2.8 Helmet Features ��11

2.9 General Description

2�9�1 Helmet Shell �� 13

2�9�2 Gas Flow Systems �� 13

2�9�3 Emergency Gas Supply System (EGS) ��16

2�9�4 Helmet Attachment to the Diver �� 17

2�9�5 Sealing Arrangement �� 18

2�9�6 Reducing Carbon Dioxide �� 19

2�9�7 Communications �� 19

2�9�8 Equalizing the Middle Ear �� 19

2�9�9 Face Port or Viewing Lens �� 19

2.10 Accessories

2�10�1 Eye Protection for Welding �� 19

2�10�2 Special Regulator Tools for REX® Regulator �� 20

2.11 Helmet Transport And Storage

2�11�1 Helmet Carrying Bag �� 21

2.12 Use of Kirby Morgan Original Replacement Parts

Chapter 3.0 Operating Instructions �� 23

3.1 Introduction

3.2 Design Purpose

3.3 First Use of Your Kirby Morgan Diving Helmet

3.4 Initial Adjustments to Your Helmet

3�4�1 Head Cushion �� 25

3�4�2 Trimming the Neck Dam �� 25

3�4�3 Adjusting the Neck Pad �� 26

3.5 Pre Dress-In Procedure

3�5�1 Pre-Dive Visual Inspection ��27

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Kirby Morgan® 47

3.6 Preparing the Helmet for Diving��28

3�6�1 Clean Face Port �� 28 3�6�2 Check Moving Parts �� 28 3�6�3 Check Communications �� 28 3�6�4 One Way Valve Check �� 28

3.7 Emergency Gas System (EGS) �� 29

3.8 Setting Up to Dive �� 34

3�8�1 Flushing Out the Umbilical �� 34 3�8�2 Connecting the Umbilical to the Helmet �� 34 3�8�3 Opening the Breathing Gas Supply to the Helmet��35 3�8�4 Fogging Prevention ��35 3�8�5 Donning The Kirby Morgan Helmet ��36 3�8�6 Testing the Breathing System ��39 3�8�7 Sealing Integrity Check �� 39 3�8�8 Adjust Regulator for Low Work Rates ��39

3.9 Removing the Helmet �� 40

3.10 Diving Procedures ��41

3�10�1 Standing By to Dive �� 41 3�10�2 Attaching the Umbilical to the Harness �� 41 3�10�3 Diver Dons Helmet �� 41 3�10�4 Diver Check Gas Flow Systems �� 41 3�10�5 Communications Check �� 41 3�10�6 Diver Ready �� 41 3�10�7 Water Entry and Descent ��41

3.11 Emergency Procedures ��42

3�11�1 Flooding �� 42 3�11�2 Inhalation Resistance �� 42 3�11�3 Gas Flow Stops �� 42 3�11�4 Demand Regulator Free Flow ��43

3.12 Post Dive Procedures ��44

3�12�1 Removing the Equipment �� 44 3�12�2 Removing the Helmet �� 44 3�12�3 Storage of the Helmet Between Dives �� 44

Chapter 4 Troubleshooting �� 45

4.1 General �� 45

4.2 Communication Malfunction �� 45

4.3 One Way Valve Malfunction �� 45

4.4 Side Valve Malfunction ��46

4.5 Water Leakage Into Helmet ��46

4.6 Demand Regulator Malfunction �� 47

4.7 Emergency Gas Supply Valve ��47

Chapter 5 Inspection and Maintenance �� 49

5.1 Routine Maintenance �� 49

5�1�1 Daily Pre-Dive Maintenance A2�3 ��49 5�1�2 Daily Post Dive Maintenance A2�6 �� 49 5�1�3 Supervisors Equipment Checks A2�4 and A2�5 �� 49

5.2 Monthly Maintenance �� 49

5.3 Yearly Maintenance �� 49

5�3�1 Overhaul/Inspection Checklist A2�1 �� 49

Kirby Morgan® 47

Chapter 6.0 General Preventative Maintenance ��51

6.1 Introduction ��51

6.2 Required tools, Sealing, Cleaning Agents, Lubrication

6�2�1 Component and Parts Cleaning �� 52 6�2�2 Component and Parts Lubrication �� 52 6�2�3 Teon® Tape �� 53 6�2�4 RTV Sealant ��53 6�2�5 Thread Locker ��53

6.3 General Cleaning & Inspection Procedures

6�3�1 O-ring Removal/Inspection/Cleaning and Lubrication �� 54

6.3.1.1 O-ring Removal �� 54

6.3.1.2 O-ring Inspection: �� 54

6.3.1.3 O-ring Reuse: �� 54

6.3.2 General Cleaning Guidelines

6.3.2.1 Mild Soap Solution for General Cleaning and Leak Detector Use �� 56

6.3.2.2 Acidic Cleaning Solution and Procedures ��56

6.3.2.3 Germicidal Cleaning Solutions and Procedure ��56

6.4 Daily Maintenance

�� 57

�� 54

6.5 Monthly Maintenance (or between jobs)

6�5�1 Locking Collar Assembly & Helmet Ring �� 58 6�5�2 Neck Dam Ring Assembly �� 58 6�5�3 Head Cushion and Chin Cushion �� 59 6�5�4 Communications Inspection �� 59 6�5�5 Lubricate Nose Block O-Rings �� 59

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6.6 REX® Demand Regulator & Exhaust System Post Dive Cleaning & Sanitizing �� 60

6�6�1 Post Dive Disassembly �� 60 6�6�2 Sanitizing �� 61 6�6�3 Post Dive Reassembly �� 62

Chapter 7.0 Breathing System Maintenance and Repairs ��63

7.1 Introduction ��63

7.2 Torque Values �� 63

7.3 One Way Valve

7�3�1 Disassembly Of The One Way Valve �� 63 7�3�2 Reassembly of the One Way Valve �� 64

7.4 Side Block Assembly �� 66

7�4�1 General �� 66 7�4�2 Removal of the Bent Tube �� 66 7�4�3 Separating the Side Block Assembly from the Helmet Shell ��66 7�4�4 Side Block Assembly Replacement �� 68 7�5�2 Cleaning and Lubricating �� 70

7.5 Defogger Valve ��71

7�5�1 Disassembly of the Defogger Valve ��71 7�5�3 Reassembly of the Defogger Valve ��71

7.6 Emergency Valve Assembly

7�6�1 Disassembly of the Emergency Valve �� 72 7�6�2 Cleaning and Lubricating �� 72 7�6�3 Reassembly of Emergency Valve �� 73

7.7 Bent Tube Assembly

7�7�1 General �� 75

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Kirby Morgan® 47

7�7�2 Removal of the Bent Tube Assembly �� 75 7�7�3 Inspection of Bent Tube Assembly �� 76 7�7�4 Reinstallation of the Bent Tube Assembly �� 76

7.8 Demand Regulator & Exhaust System Overhaul �� 77

7�8�1 System Disassembly �� 77

7.9 Cleaning REX

7�9�1 Precautions for Cleaning ��82 7�9�2 Cleaning Instructions �� 82

®

Regulator Parts �� 82

7.10 REX® Regulator Re-Assembly �� 84

®

7.11 Testing the REX

7�11�1 REX® Adjustment Troubleshooting �� 90

Demand Regulator for Proper Adjustment ��90

7.12 Oral/Nasal Mask �� 91

7�12�1 Oral/Nasal Removal �� 91 7�12�2 Inspection of Oral/Nasal �� 91 7�12�3 Oral/Nasal Replacement �� 91

7.13 Reinstalling the Regulator on the Helmet

�� 92

7.14 Overpressure Relief / Bleed Valve Overhaul Procedures ��94

7�14�1 Overpressure Relief Valve �� 94 7�14�2 Overpressure Relief Valve Disassembly and Cleaning �� 94 7�14�3 Overpressure Relief Valve Reassembly �� 95 7�14�4 Overpressure Relief Valve Lift Check/Setting �� 95

Chapter 8 Corrective Maintenance ��97

8.1 General �� 97

8.2 Helmet Shell Inspection��97

8.3 Nose Block Assembly �� 98

8�3�1 Nose Block Assembly Removal �� 98 8�3�2 Nose Block Device Replacement �� 98

8.4 Handle and Weights ��99

8�4�1 Handle Removal �� 99 8�4�2 Handle Replacement �� 99 8�4�3 Side Weight Removal �� 100 8�4�4 Weight Replacement �� 101 8�4�5 Top Weight Removal �� 101 8�4�6 Top Weight Replacement �� 101

8.5 Face Port �� 102

8�5�1 General �� 102 8�5�2 Face Port, Port Retainer, and Nose Block Device Removal �� 102 8�5�3 Face Port, Port Retainer and Nose Block Replacement �� 103 8�5�4 Special Note Regarding Ports �� 105 8�5�5 Port Retainer �� 105

8.6 Neck Dam �� 106

8�6�1 Removal of the Neck Dam �� 106 8�6�2 Neoprene Neck Dam Replacement �� 106 8�6�3 Latex Neck Dam Replacement �� 109 8�6�4 Trimming a Latex Neck Seal �� 110

8.7 Neck Dam Pull Strap �� 111

8�7�1 Neck Dam Pull Strap Removal �� 111 8�7�2 Neck Dam Pull Strap Replacement �� 111

8.8 Chin Strap

8�8�1 Chin Strap Removal �� 111

�� 111

Kirby Morgan® 47

8�8�2 Chin Strap Replacement �� 111

8.9 O-Ring Seal Replacement �� 112

8.10 Helmet Ring �� 113

8�10�1 Helmet Ring Repairs �� 113

8.11 Sealed Pull Pins

8�11�1 Removal of Sealed Pull Pins �� 113

8�11�2 Replacement of Sealed Pull Pins �� 113

�� 113

8.12 Swing Tongue Catch �� 114

8�12�1 Disassembly of the Swing Tongue Catch �� 114

8�12�2 Reassembly of the Swing Tongue Catch �� 115

8.13 Locking Collar

8�13�1 Locking Collar Removal �� 116

8�13�2 Locking Collar Disassembly �� 117

8�13�3 Locking Collar Reassembly �� 118

8.14 Head Cushion and Chin Cushion

8�14�1 Head Cushion Foam �� 119

8�14�2 Chin Cushion Foam �� 119

�� 116

�� 119

8.15 Communications System �� 120

8�15�1 General �� 120

8�15�2 Earphone Inspection �� 120

8�15�3 Removal of Communications Assembly �� 121

8�15�4 Replacement of Communications Assembly �� 121

8�15�5 Microphone Replacement �� 121

8�15�6 Earphone And Wire Assembly Replacement �� 122

8�15�7 Waterproof Connector �� 123

8.15.7.1 Connector Removal �� 123

8.15.7.2 Connector Replacement �� 123

8�15�8 Terminal Connections in the Waterproof Connector �� 123

8�15�9 Communications Posts �� 125

8.15.9.1 Communications Post Removal �� 125

8.15.9.2 Communications Post Replacement �� 125

Chapter 9.0 Accessories for the Kirby Morgan 47 �� 127

9.1 Introduction �� 127

9.2 Low Pressure Inator Hose �� 127

9�2�1 Installation of the Low Pressure Inator Hose �� 127

9�3�1 Weld Lens Assembly Installation �� 128

9.5 Use of Quick Disconnect �� 129

9.4 Weld Shield Assembly �� 129

9�4�1 Weld Shield Assembly Installation �� 129

Table of Equivalents �� 131 Appendix 1: Torque Specications �� 132 Note on Torque Specications �� 133

Checklist, Maintenance, and Pre-Dive Inspections �� 133

Appendix A2 Maintenance and Inspection Procedures �� 134 Appendix 3 Supply Pressure Requirements & Tables �� 136

Appendix 3 Table 1 Work Rate Expressed as Respiratory Minute Volume (RMV)* �� 137 Appendix 3 Table 2 REX® Regulator Low-Pressure Compressor Supply Pressure Requirements Table Continued* �� 138 Appendix 3 Table 3 Topside High-Pressure Regulator Settings for use with the Kirby

Kirby Morgan® 47

CAUTION

DANGER

WARNING

Definition 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.

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

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

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

If English is not your native language and you have any difculty understanding the language of any warnings as they

appear in the manual, please have them translated.

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

Este es un aviso importante. Sirvase mandario traducir.

Quest è un avviso importante. Tradurlo.

Ceci est important. Veuillez traduire.

Diese Mitteilung ist wichtig. Bitte übersetzen lassen.

If you have any questions concerning this manual or the operation of your helmet, contact KMDSI (805) 928-7772 or by Email at KMDSI@KirbyMorgan.com or Dive Lab Inc. (850) 235-2715 or at Divelab@aol.com

IMPORTANT: A word about this manual. We have tried to make this manual as comprehensive and factual

as possible. We reserve the right, however, to make changes at any time, without notice, in prices, colors, materials,

equipment, specications, models and availability. Since some information may have been updated since the time of printing, please contact your local KMDSI dealer if you have any questions. To nd a dealer near you, please see the

Kirby Morgan web site, www.kirbymorgan.com. Periodically KMDSI Operations and Maintenance Manuals are reviewed. Any updates/changes will be posted on the KMDSI website and may be downloaded for insertion/correction.

Important Safety Information:

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

Kirby Morgan® 47

WARNING

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

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

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

Read this manual before using or maintaining the helmet, even if you have experience with other diving helmets. If you have purchased the helmet new from a dealer, be sure to send in the warranty registration card so we may keep you informed of any safety notices that affect this product. If you resell or loan this helmet to another diver, be sure this manual accompanies the helmet and that the person reads and understands the manual. In addition to the manual a log book should be used to log all repairs, maintenance and use.

Diving is a life threatening occupation. Even if you do everything right you can still be killed or injured. None of the models of Kirby Morgan helmets or masks can prevent accidents, injuries or death due to improper training, poor-health, improper supervision, improper job requirements, improper maintenance or acts of God.

This 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.

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

Helmet shells can be re-gel coated by authorized/certified KMDSI trained technicians that have received fiberglass training by KMDSI. Helmets that are to be painted for cosmetic purposes, should be first, certified free of fiberglass damage by an authorized KMDSI technician certified in fiberglass repair. A log entry should be made in the helmet log that the helmet was free of damage prior to painting. Keep in mind other KMDSI technicians can refuse to work on helmet shells that have previously been painted or repaired by non KMDSI certified persons.

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.

Kirby Morgan® 47

WARNING

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: KMDSI@kirbymorgan.com.

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

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

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

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

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

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

space craft use, or for chemical warfare use. The helmet must never be used by persons in poor physical condition, by persons with previous head, neck, or back injuries which could be aggravated by its use. The helmet should not be used by persons under the influence of drugs or alcohol. Furthermore, infants, children, or persons under the age of 18 should never wear KMDSI helmets and masks. Failure to pay heed to the above could result in serious injury or death.

Never use the helmet without first completing all pre-dive maintenance and set up pro-

cedures.

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 flooding.

Surface-supplied diving can be a strenuous activity. The Kirby Morgan 47 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 47. Use of the Kirby Morgan 47 with a pre-existing physical/medical condition may result in death or serious injury.

The information contained in this manual is intended to aid the user in optimizing the performance of this helmet. The application of some of this information will depend on the diving situation and the use of associated equipment.

Many countries have 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.

Kirby Morgan® 47

WARNING

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

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.

Kirby Morgan® 47

Defog Free Flow

Valve Knob

Sideblock

Handle

Helmet Shell

Port Retainer

EGS Valve

Non-Return Valve

Pull Pin

Oral Nasal Mask

Equalization Device

Regulator Adjustment

Knob

The Kirby Morgan® 47 helmet

Communications

Module

®

REX

Exhaust

System

Purge Button

R

E

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Kirby Morgan® 47

STOP!

BEFORE GOING FURTHER-

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

Chapter 1

General Information KMDSI Products

1.1 Introduction

The Kirby Morgan Corporation was started in 1965. The copper and brass “Heavy Gear” or “Standard Dress” helmets wer e the rst hel mets manufactu red by the company. Over the years Kirby Morgan designed, manufactured and sold many different helmets and masks for commercial divers.

Staying active in commercia l d iving 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 fty-seven diving hel mets a nd 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, wit hout 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, d iving medical specia lists, diving organ ization administrators and their supporting personnel has contributed to the current state of the art of diving.

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

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

Bev Morgan, Chairman of the Board

Kirby Morgan Dive Systems, Inc.

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

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

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

Kirby Morgan® 47

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1.2 Full-Face Masks and Manifolds

KMB® 18 A/B

approved and ™ marked

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

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

approved. It meets and surpasses

European standards for regulator performance.

The KMB 18B Band Mask frame is constructed of hand laid 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 similar to the KMB 18, with many parts on the KMB 18B being interchangeable wit h 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 i ntermediate air pressure against the valve sealing pressure inside the regulator. This enables the regulator to instantly adjust to changes in line pressure. The balanced regulator is adjustable for a wide range of intermediate pressures between 90 PSIG – 250 over ambient pressure (6.2 – 17 bar).

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

Both the KMB 18 and KMB 28 are

approved.

SuperMask M-48

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w/ Scuba Pod

Kirby Morgan® 47

KMACS-5

w/ No Communications

approved and ™ marked

The SuperMask M-48 is an innovative new design in a full-face mask. It provides the diver with all the comfort of a full-face mask with the convenience of changeable second st age regulators as well as the ability to use a snorkel wit hout 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 mout h for com mun ications. With the mouthpie ce in, the regulator may be used without the pod being sealed to the mask.

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.

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-pressu re cylinders. T he 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.

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.

SuperMask M-48

w/ Rebreather pod

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

Kirby Morgan® 47

1.3 Kirby Morgan Diving Helmets

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

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

The SuperLite

®

27, and Kirby Morgan models 37, 37SS,

®

-17 A/B was rst developed in 1975

™

marked.

®

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.

®

17C the

The SL-17 A/B helmet system consists primarily of two major components: the neck dam/yoke assembly, and t he helmet. To don the helmet, the diver rst slips the a ngled neck dam wit h t he attached yoke over thei r 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.

Other features that are common to all Kirby Morgan

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helmets include:

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

Kirby Morgan® 47

The Kirby Morgan

®

37 Commercial Diver’s Helmet

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

The helmet comes with the large tube SuperFlow

®

350 adjustable demand regulator which provides an easier breathing gas 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.

The SuperLite

®

27® Commercial Diver’s Helmet has

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

®

SuperLite

27

®

approved and ™ marked

Kirby Morgan® 47

®

The chrome plated machined brass helmet neck ring houses the sealed pull pins and provides protection for the bottom end of the helmet. Like the SL-17K, 37 and 17C, the diver is provided with an internally adjustable chin support. This support, along with the adjustable neck pad on the locking collar, gives the diver a comfortable, secure, custom t.

The quick-cha nge 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 tube adjustable demand regulator. The helmet is available in the umbilical over the shoulder, “B” conguration only.

®

350 large

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. T he REX

®

Demand Valve, wit h 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.

Kirby Morgan® 47

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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

™

Valve

Exhaust System. It's recommended for div-

®

57 also includes our Quad

ing 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.

• Elim ination of th readed 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® 47

®

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 K i rby Morgan 37SS featur es 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

Kirby Morgan® 47

WARNING

CAUTION

Chapter 2

Description & Operational Specications

Kirby Morgan 47

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 qualied diver. We highly recommend that all divers should train, under controlled conditions, in the use of any model of commercial diving helmet that they have not previously used or trained in, prior to use on the job, until they have mastered the skills required to use their helmet correctly.

This section includes detailed descriptions of the Kirby Morgan 47, as well as important operational specications. With the exception of the regulators, all parts are interchangeable.

2.1 CR Marking

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

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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 valve REX

Category of PPE: III

®

.

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:

CE Mark

KIRBY MORGAN

DIVE SYSTEMS, INC.

1430 Jason Way,

Santa Maria, CA 93455

2049

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 serial number;

5. the year of production;

6. CE marking:

;

7. number of notied body.

The user cannot:

• remove the mark from the frame of the

helmet;

• modify or counter feit th e d a t a r e ported

on the mark.

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

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.

Kirby Morgan® 47

WARNING

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: 2049

2.3 Other Marking

The helmet Kirby Morgan 47 meets or exceeds all requirements of NPD, Health and Safety (U.K.), United States Navy and ADCI United States.

2.4 Product Specifications

Weight: KM 47 - 30.96 pounds Helmet Shell: Fiberglass, polyester resin, polyester gel coat, and carbon bers Regulator Body - Stainless steel Control Knobs: ABS plastic 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 Silicone Lubricant. Krytox also acceptable.

®

and Halocarbon® are

®

MS4

2.5.2 Minimum Operating Temperature

The KM-47 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-77 however work is underway to produce one. The the standard shroud PN# 525-100 can be modied to work. for more information contact Dive Lab Inc. WWW.divelab.com

Without a hot water shroud, the diver may be subject to hypothermia due to cold gas inspiration temperatures. Kirby Morgan makes no physiological recommendations regarding minimum safe operating temperatures for divers using this helmet.

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.

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@ KirbyMorgan.com or Dive Lab Inc. (850) 235-2715 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.

2.5 Regulator Performance

2. 5 .1 REX® Regulator

The REX high performance. The regulator has been tested at Dive Lab at Panama City, Florida. It meets or exceeds all current U.S. Navy and European diving standards.

®

regulator on the Kirby Morgan 47 offers

2.6 Cage Code

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

2.7 Operational Specifications &

Limitations

-Umbilical minimum I.D. 3/8” (9.5 mm) of not more than two sections, total length not to exceed 600 feet (183m).

Recommended over-bottom (OB)gas supply pressure for best performance at depths are calculated by the formula (fsw x 0.445+14.7) + recommended p.s.i g.

The calculations for specic depths are shown in the Appendix. 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

WARNING

DANGER

WARNING

WARNING WARNING

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.

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.

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.

It is important for the user/diver to take excessive currents into consideration. The exhaust system on the REX

®

Regulator will help prevent water intrusion when diving in heavy currents. The REX

®

exhaust system does not limit the diving depth.

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

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

Kirby Morgan® 47

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

If you have any questions regarding proper set-up, operation, or maintenance of your 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

2.8 Helmet Features

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

The KM 47 was initially developed 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 47 takes the proven design features of our world famous SuperLite advanced design features of the SuperLite some balance renements, and our REX and you have a superb diving helmet. Exemplifying our adherence to the highest quality and proven superior work performance, the KM 47 is another outstanding helmet from Kirby Morgan.

The KM 47 incorporates the innovative locking system and communications system of the SuperLite 27 onto a larger SuperLite The 47 features the REX tor which provides superb breathing gas ow during peak work output.

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,

®

17 A/B and blends in many of the

®

17 size berglass shell.

®

adjustable demand regula-

®

27. Add in

®

regulator,

®

Kirby Morgan® 47

WARNING

allows for easy, efcient maintenance of the communications in the helmet.

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

should be completed. The divers and the topside team must be properly trained and have the proper safety equipment. All helmets and suits can leak water under certain conditions. Divers should use extreme caution when diving in contaminated waters.

The KM 47 has the REX

®-3®

exhaust system, which is recommended for diving in contaminated water. Other helmet features which are common to most KMDSI helmets include:

• the face port and retainer ring

• communications components

• the oral/nasal mask

• the nose block device

• the air train

• the side block, emergency valve, and non-return valve

Many of the breathing system components on these helmets are also compatible with the KMB 18B and 28B full-face masks and the EXO-26. 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 47.

1) The face port (or view port) area remains unchanged from the SuperLite

®

-17B. The side block is also the same. Many of the components in these sub-assemblies are interchangeable between the 17B and the KM 47.

2) The bottom of the KM 47 berglass helmet mates with the helmet ring that is installed at the factory. This metal 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 47 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 47 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) A new 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 47.

8) A system of two sealed pull pin locks is on the KM

47. 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 sand or other debris can reach the interior of these locks to interfere with their operation.

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 polyester foam inside. The 17B head cushion should not be used in the KM 47 because the design of the head cushions is different. Only genuine Kirby Morgan KM 47 head cushions should be used to assure proper operation and comfort.

10) The handle that is tted to the top of the helmet and the port weight are areas that can be used as mounting brackets for lights, TV cameras, etc.

11) The communications system is a modular, quick change design.

12) The exhaust system is a three valve design, the

®

REX

-3, that helps to keep the helmet exceptionally

dry.

Kirby Morgan® 47

DANGER

CAUTION

WARNING

DANGER

2.9 General Description

2.9.1 Helmet Shell

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

On the Kirby Morgan helmets, the helmet ring is attached to the base of the helmet shell at the KMDSI factory. This chromed brass helmet ring must not be removed by anyone other than the factory or a KMDSI approved repair center.

2.9.2 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 component.

Gas Flow To Air Train

EGS Gas Supply

Main Gas Supply

Auxiliary L.P. Port

Gas Flow To Regulator

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

Never attempt to remove or service the chromed ring on the base of the helmet shell. Improper servicing of this ring can lead to helmet ooding and death.

The bent tube assembly for the KM47 is a unique design and is not interchangeable with the bent tube assembly used on other Kirby Morgan masks and helmets.

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.

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

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

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

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

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

Kirby Morgan® 47

FEATURES OF THE KM 47

Gas Supply Non-Return Valve prevents loss of gas pressure

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

Emergency Gas Supply Valve provides the emergen-

cy breathing gas to the diver.

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.

Silicone Oral Nasal Mask is made of

a superior silicone material which is hypoallergenic and has a longer work life than latex.

Air Train

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

diffuses the incoming

Nose Block Device

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

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.

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.

REX® Regulator

has exceptional breathing characteristics and an extremely low work-of-breathing.

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.

Kirby Morgan® 47

WARNING

The gas ow continues out through the regulator exhaust system, or into the oral nasal mask by means of the oral/nasal valve. The diver can breathe from this ow of gas if the demand regulator malfunctions. The gas then ows into the regulator and out through the regulator exhaust. From there it can exit through either of the exhaust valves and out through the whiskers.

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

The side block on the helmet is drilled and tapped to accept low-pressure inator hoses. This allows the diver the capability to inate variable volume dry suits. It is tapped with a 3/8-24 thread orice, standard for American rst stage SCUBA regulator’s low-pressure auxiliary ttings. The port is shipped plugged at delivery. This ination capability does not

signicantly interfere in any way with the breathing characteristics of the regulator during normal use providing a limiting hose is used. The dry suit ination hose should be one that is restricted to ow less than 100 LPM.

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

Regulator Mount Nut

Starboard Whisker

Exhaust Main Body

Valve Seat

Water Dump valve

Inlet valve

Thrust Washer

Horseshoe

Tie Wrap

Main tube

Exhaust Valve

Tie Wrap

Regulator body

Roller lever

Port Whisker

Spring

O-ring

Spacer

Sleeve

Exhaust valve

Nut

Spacer

Diaphragm

Knob

Roll pin

Adjustment shaft

Cover

Exploded view of the REX® regulator.

O-ring

Nipple tube

Adjustment lock nut

Washer

Cover Retaining Ring

Kirby Morgan® 47

WARNING

CAUTION

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

ebbs and stops. When the diver exhales, the supply gas stays off as the exhalation gas ows through the regulator body, out the regulator exhaust valve, through the whisker, and out into the water. The whiskers deect the exhaust bubbles away from the face port to keep the diver’s view clear.

Otherwise, the hose should be equipped with a ow restrictor (P/N 555-210) to limit ow in the event the hose ruptures or is severed.

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

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

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

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

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

Low pressure hoses may be connected to the side block.

®

The REX divers inhalation and opens the inlet valve, matching the diver’s need. The regulator continues to match the diver’s inhalation as the rate increases, peaks, then

demand regulator senses the start of the

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

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

2.9.3 Emergency Gas Supply System (EGS)

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

The KMDSI Overpressure Relief Valve, (part number 200-017) is fully adjustable and rebuildable and has been designed to relieve any over-pressurization of

Kirby Morgan 47 Operation And Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual