Kirby Morgan 77 User Manual

Kirby Morgan 77

WARNING

Chapter 3.0

Operating Instructions

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.

3.1 Introduction

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

A proper training program in a calm, clear body of water should be undertaken. If the diver has not used a particular Kirby Morgan helmet before, he must not dive with the helmet without proper training.

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

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

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

3.2 Design Purpose

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

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

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

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

Kirby Morgan 77

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

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

All diving always involves the risk of decompression sickness. Omitted decompression due to loss of gas supply or other accidents can cause serious injury or death. The use of the Kirby Morgan helmets or masks cannot prevent this type of injury.

KMDSI manufactures a complete Air Control System, the KMACS 5™ with integrated communications and pneumofathometer. This portable system can be operated on either a high pressure air supply or on a low pressure compr essor. The Ai r Control System ha s a specially designed high pressure regulator that reduces high pressure air and provides an adequate ﬂow to support divers to a depth of 130 fsw (40 msw)

The helmet demand regulator and side block assemblies have been designed to operate with a supply pressure from 130 p.s.i.g. (8.8 bar) to 225 p.s.i.g. (16 bar) over ambient pressure. This wide operating range allows ﬂexibility when using various gas supply systems.

For maximum breathing performance it is desirable to maintain an over bottom supply pressure in accordance with the low-pressure and high-pressure supply tables found in Chapter 2 of this manual. With the many different gas supply console conﬁgurations in use, it is important to ensure that the gas supply system used, is capable of supplying the helmet with the necessary pressure and ﬂow of gas to allow the diver to work safely and efﬁciently.

There are also detailed checklists for the set-up and maintenance of your helmet on the Dive Lab web site at www.divelab.com.

3.3 First Use of Your Kirby Morgan Diving Helmet

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

Early production of the REX 77 helmet had a much different surface ﬁnish than what is found on current production runs.

Earlier helmets shells and components were ﬁnished using a combination of glass and Stainless Steel beads; this gave a dull or ﬂat looking surface ﬁnish. Later shipments have a surface ﬁnish with a much smoother and almost shiny appearance. Although the parts are not shiny, the surface ﬁnish is very smooth. A Scotch-Brite pad will remove buildup of unwanted surface deposits on both older, and newer REX 77 helmets. It can also be used to give the main helmet components on newer helmets, a satin (brushed ) ﬁnish.

, (or similar non metallic), scouring

High pressure supply regulators and associated piping systems for surface supplied diving with Kirby Morgan helmets and masks must be capable of delivering a minimum of 3.2 acfm to the diver at depth. Only systems that can deliver the required gas ﬂow should be used.

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

WARNING

3.4 Initial Adjustments to

WARNING

O-ring

Split Ring

Neck dam

Stepped Ring

Pull Strap

Screw

Your Helmet

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

3.4.1 Head Cushion

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

The center top/rear foam is very dense to reduce

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

compression and spring-back. This reduces the tendency of the helmet to ride up when underwater. Do not replace this rigid foam with a soft foam. A softer foam is used on the sides and around the bottom of the head cushion.

Kirby Morgan 77

The head cushion should be adjusted for best ﬁt.

dam opening so that the two “edges” of the neck dam are parallel. The neck dam must be under slight tension but must not be stretched beyond its normal length. Trim the neck dam with the largest, sharpest scissors available, in order to make as few cuts as possible. There must be no jagged edges on the neck dam or it may tear.

Trim only 1/4 inch off the neck dam at a time. When you are done, the neck dam must be just tight enough

The diver’s head can be moved forward into the oral nasal mask by adding layers of additional foam at the rear of the head cushion. Do not add to much foam to the rear of the head cushion, as this may position the diver’s chin too far into the oral/nasal mask and create an uncomfortable ﬁt. The diver’s head can be moved up or down in the helmet by decreasing or increasing the foam pads at the top of the head cushion.

Usually, a diver with a small head will use all the foam that comes with a new hat. A diver with a larger head will need to remove a layer of foam in the center top and back of the head cushion. The foam may be cut with scissors to provide a better ﬁt, or more foam can be added to give a tighter ﬁt.

The chin cushion can also be adjusted if necessary.

3.4.2 Trimming the Neck Dam

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

The neck dam must be trimmed to ﬁt your neck. To trim the neck dam, have your tender hold the neck

Neck Dam components.

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

Kirby Morgan 77

CAUTION

Hinge bolt

Nut

Locking collar

Neck pad

Adjustment nut

Washer

Screw

Washer

T-washer

Teflon Washer

Washer

so that it does not leak. This may feel a bit snug out of the water, but should be comfortable underwater.

If you have a neoprene neck dam, it may also need to be stretched for it to ﬁt properly. Trim the neck dam until it is still snug, then stretch it by sliding it over a scuba tank and allowing it to sit overnight. If you still cannot get the proper ﬁt by stretching the neck dam, it must be trimmed further. Do not trim more than 1/4 inch at a time.

Trimming the neck dam.

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

3.4.3 Adjusting the Neck Pad

Another component that controls the ﬁt of the Kirby Morgan helmet is the adjustable neck pad. The neck pad, which is mounted on the locking collar, slides back and forth along the locking collar body for adjustment to ﬁt different divers. Two screws and adjustment nuts lock the neck pad plate to the locking collar. Loosening these screws from the mount nuts allows the neck pad to be adjusted.

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

The following procedure requires a diver and tender. You do not need to have the air on to the helmet if you do not use the neck dam ring assembly. If the neck dam assembly is used, the diver must have air to the helmet to breathe.

With the helmet face down on a suitable surface, pull and turn each of the sealed pull pins until they are locked open. Swing the locking collar/neck pad as-

Locking Collar components.

Kirby Morgan 77

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sembly out away from the base of the helmet. Slightly loosen the screws until the neck pad can slide back and forth. Be sure each of the head cushion snaps are attached to their corresponding ﬁtting inside the helmet.

Pick up the helmet and pull the nose block device knob out fully. Position the helmet on your head so the oral nasal is in the proper position on your face, covering your nose and mouth. Turn the sealed pull pins to the locking position with the ridge on the pins engaging the notch in the sleeve and the pins fully retracted.

Tilt your head forward so the lock i ng colla r/neck pad assembly may be swung forward and locked up into its closed position. The sealed pull pins must snap into place on the locking collar.

Lift your head back up and slide the neck pad forward until it is snug but comfortable. Mark the position of the neck pad on the locking collar using an indelible marker. Pull the sealed pull pins out to their unlocked position and let the locking collar open.

3.5.1 Pre-Dive Visual Inspection

Visually inspect the exterior and interior of the helmet.

1) Inspect the regulator cover for any damage. The purge button must work.

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

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

3) Inspect the O-ring on the neck dam ring assembly. The O-ring must be in place, undamaged, and lubricated.

Remove the helmet. Position the neck pad plate on the locking collar at the marked position and tighten the screws on each side. After the adjustment screws are tightened, don the helmet again, tilt your head forward and lock the locking collar/neck pad assembly. Move your head in various positions to make sure the pad is adjusted for comfort.

The helmet is now adjusted for your head. It should need no further adjustment unless another diver uses the helmet.

3.5 Pre Dress-In Procedure

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

The O-ring on the neck dam ring assembly on the Kirby Morgan helmet must be in place and in good condition. It must be properly lubricated for smooth operation. Without a proper functioning O-ring the helmet will leak and possibly ﬂood. Drowning could result.

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

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

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

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

8) Inspect the sealed pull pin on each side of the helmet. They must engage and disengage properly.

9) Make sure the head cushion and chin cushion are properly fastened inside the helmet. The chin strap should be open as wide as possible.

Kirby Morgan 77

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10) Check the screws on the port retainer . They must be adjusted to the proper torque setting speciﬁcations noted in Appendix 1 of this manual. Binder head screws are used in this application for their self locking characteristics.

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

3.6 Preparing the Helmet for Diving

3.6.1 Clean Face Port

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

3.6.2 Check Moving Parts

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

3.6.3 Check Communications

Check the communications system for proper operation. Put the helmet on and talk to an assistant on the ampliﬁer. If you are by yourself, with the helmet off take the helmet near the ampliﬁer and tap on each earphone and the microphone, listening to the taps on the ampliﬁer/speaker. Talk into the ampliﬁer/ speaker feeling the vibration on each earphone and the microphone with your ﬁngertips. Check the ﬁt and tightness of the comm module mount nut.

3.6.4 One Way Valve Check

The one way valve must be tested daily, prior to commencement of diving operations.

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

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

You can test the one way valve by connecting the bailout bottle to the emergency valve and pressurizing the sideblock. There must be no gas leakage through the one way valve.

WARNING

The one way valve must be tested daily,

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prior to commencement of diving operations. Failure of the one way valve could cause serious injury or death.

Kirby Morgan 77

3.7 Emergency Gas System (EGS)

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

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

You can also test the one way valve by attempting to suck air through the valve. The emergency valve must be open for this test to work properly. If you are able to suck any air through the valve it is not working properly.

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

Diver donning a complete bail-out system.

Most commercial divers wear a harness (separate from the weight belt) that is used for several purposes. The harness is ﬁtted with large metal rings (usually brass or stainless steel). The umbilical is hooked into one of these rings to keep any strain off the helmet. In addition, the rings on the harness are used to hang tools and other equipment. Usually the harness is also designed to provide a means of lifting an unconscious diver from the water. This harness is the best method of securing the emergency breathing gas to the diver.

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Kirby Morgan 77 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual