Kirby Morgan SuperLite 17B Operation And Maintenance Manual

WARNING

SuperLite® 17B Helmet

Operations and Maintenance Manual

KMDSI Part # 100-001

™

Kirby Morgan Dive Systems, Inc.

1430 Jason Way

Santa Maria, CA 93455, USA

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

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

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

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

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

that are not manufactured by KMDSI is illegal.

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

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 120613005

SuperLite® 17B

Warranty Information

Kirby Morgan Dive Systems, Inc. warrants every new mask, helmet, or KMACS 5 Air Control

System to be free from defects in workmanship for a period of three hundred sixty 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 x 229. You must have a return authorization from KMDSI prior to the return of any item, Upon approval from KMDSI, return the defective part, freight prepaid, to the KMDSI plant. The part will be repaired or replaced at no charge as deemed necessary by KMDSI.

This warranty becomes null and void if:

1) The product is not registered with KMDSI within ten (10) days of purchase.

2) The product has not been properly serviced and/or maintained according to the appropriate KMDSI manual. In addition, the user is responsible to ensure that all product updates as recommended by KMDSI have been performed.

3) Unauthorized 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.

SuperLite® 17B

Record Of Changes

It is the responsibility of the owner of this product to register their ownership with Kirby Morgan Dive Systems, Inc., by sending the warranty card provided. This card is to establish registration for any necessary warranty work and as a means of communication that allows KMDSI to contact the user regarding this product. The user must notify KMDSI of any change of address by the user or sale of the product.

All changes or revisions to this manual must be recorded in this document to ensure that the manual is up to date. Quantities marked in parenthesis.

Change Number Date Description of Change

1 05/28/2008 Reworded: 2.1 Product Specications, 2.4 Operational Specications & Limitations,

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

Added: Appendix A2, 3 and 4

®

Moved: 2.4 Operational Specications & Limitations, The SuperFlow Regulator Image Rotated and Scaled to t.

Removed: Table 1 and Table 2 from chapter 2.

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

Page 16 First paragraph Part number added to Hard Shell. Page 17 Second paragraph 77 added to list of helmets.

Chapter 1 rearranged and CE text added to KM-77 description.

Pg 63 and 64 Chapter 5 made to two columns format and font changed to lower case instead of all caps.

Page 65 Added Whisker Clamp Replacement Kit: Part # 525-032. Page 66 Corrected text to read “SL 17” instead of “KM 37 and 57” in 6.2, last

sentence and photo caption. Page 102 step 17 corrected, "sssembly" to read "assembly."

Page 173 Torque Specication corrections.

Page 174 Added note about thread locking compound.

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

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

Demand

SuperLite® 17B

WARNING

Change Number Date Description of Change

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

"resuse" corrected to reuse in step 7. Corrected 35 inch pounds to 20 inch pounds in step 1 of section 8.10.1.2. Corrected 35 inch pounds to 20 inch pounds in step 3 of section 8.10.1.2.

Page 175: Location #94's part number corrected from 530-045 to 530-040. Added location #'s 6, 107 and 152a.

4 07/23/2009 CE material added

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

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

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

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

9 04/06/2011 Updated earphones throughout manual

10 06/17/2011 Changed 61 meters to 67 meters in Appendix 3 Table 3 SuperFlow

High Pressure Regulated Source

11 10/17/2011 Updated CE notifying body number from 0496 to 2049

12 05/09/2012 Updated CE notifying body address

13 05/13/2012 Updated copyright date to roman numerals

®

350 Regulator

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

SuperLite® 17B

Table Of Contents

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

Chapter 1 General Information KMDSI Products �� 1

1.1 Introduction

1.2 Full-Face Masks and Manifolds

1.3 Kirby Morgan Diving Helmets

Chapter 2 Description & Operational Specications - SuperLite®-17B �� 9

2.1 CR Marking

2.2 CE Certication

2�2�1� CE Marking �� 9

2�2�2� Notied Body �� 10

2.3 Product Specications ��10

2.4 Regulator Performance �� 10

2.5 Cage Code �� 10

2.6 Operational Specications & Limitations

2.7 Helmet Features

2.8 General Description �� 13

2�8�1 Helmet Shell �� 13

2�8�2 Gas Flow Systems �� 13

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

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

2�8�5 Sealing Arrangement �� 18

2�8�6 Reducing Carbon Dioxide �� 19

2�8�7 Communications �� 20

2�8�8 Equalizing the Middle Ear �� 20

2�8�9 Face Port or Viewing Lens �� 21

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

2.9 Accessories �� 21

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

2�9�2 Hot Water Shroud ��22

2�9�3 Special Regulator Tools �� 22

2.10 Helmet Transport And Storage �� 23

2�10�1 Helmet Carrying Bag �� 24

2.11 Use of Kirby Morgan Original Replacement Parts

Chapter 3 Operating Instructions �� 25

3.1 Introduction ��25

3.2 Design Purpose

3.3 First Use of Your Kirby Morgan Diving Helmet

3.4 Initial Adjustments to Your Helmet

3�4�1 Head Cushion �� 27

3�4�2 Adjusting the Neck Dam �� 28

3.5 Pre Dress-In Procedure

�� III

�� XI

�� 1

�� 2

�� 4

�� 9

�� 10

�� 11

�� 24

�� 25

�� 27

�� 29

SuperLite® 17B

3�5�1 Pre-Dive Visual Inspection ��29

3.6 Preparing the Helmet for Diving��30

3�6�1 Clean Face Port �� 30 3�6�2 Check Moving Parts �� 30 3�6�3 Check Communications �� 30 3�6�4 One-Way Valve Check �� 30

3.7 Emergency Gas System (EGS) �� 31

3.8 Setting Up to Dive �� 35

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

3.9 Diving Procedures

3�9�1 Standing By to Dive �� 43 3�9�2 Attaching the Umbilical to the Harness �� 43 3�9�3 Diver Dons Helmet �� 43 3�9�4 Diver Check Gas Flow Systems �� 43 3�9�5 Communications Check �� 43 3�9�6 Diver Ready �� 43 3�9�7 Water Entry and Descent ��44

�� 43

3.10 Emergency Procedures ��44

3�10�1 Flooding �� 44 3�10�2 Inhalation Resistance �� 44 3�10�3 Gas Flow Stops �� 44 3�10�4 Demand Regulator Free Flow ��45

3.11 Post Dive Procedures ��45

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

Chapter 4 Troubleshooting ��47

4.1 General �� 47

4.2 Communication Malfunction �� 47

4.3 One Way Valve Malfunction �� 47

4.4 Side Valve Malfunction ��48

4.5 Water Leakage Into Helmet ��48

4.6 Demand Regulator Malfunction

4.7 Emergency Gas Supply Valve

�� 49

Chapter 5 Inspection and Maintenance �� 51

5.1 Routine Maintenance �� 51

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

5.2 Monthly Maintenance �� 51

5.3 Yearly Maintenance �� 51

SuperLite® 17B

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

Chapter 6 General Preventative Maintenance ��53

6.1 Introduction ��53

6.2 Required tools, Cleaning Agents, Lubrication

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

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

6�2�3 Teon® Tape �� 55

6�2�4 RTV Sealant ��55

6�2�5 Thread Locker ��55

6.3 General Cleaning & Inspection Procedures

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

6�3�2 General Cleaning Guidelines �� 56

6�3�2�1 Mild Soap Solution for �� 57

General Cleaning and Leak Detector Use �� 57

6.3.2.2 Acidic Cleaning Solution and Procedures ��57

6.3.2.3 Germicidal Cleaning Solutions and Procedure ��57

�� 53

�� 55

6.4 Daily Maintenance �� 59

6.5 Monthly Inspections �� 61

6�5�1 Quad-Valve™ Exhaust System ��61

6�5�2 Emergency Valve Assembly �� 62

6�5�3 Steady Flow/Defogger Valve ��62

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

6�5�5 Neck Clamp and Yoke Assembly �� 62

6�5�6 Latch Catch Mechanism �� 62

Chapter 7 Breathing System Maintenance and Repairs ��63

7.1 Introduction ��63

7.2 One Way Valve �� 63

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

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

7.3 Side Block Assembly��65

7�3�1 General �� 65

7�3�2 Side Block Assembly Removal �� 65

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

7�3�4 Side Block Assembly Replacement �� 68

7.4 Defogger Valve ��69

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

7�4�2 Cleaning and Lubricating �� 69

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

7.5 Emergency Valve Assembly

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

7�5�2 Cleaning and Lubricating �� 71

7�5�3 Reassembly of Emergency Valve �� 72

7�5�4 Leak Testing the EGS Valve ��73

7.6 Bent Tube Assembly

7�6�1 General �� 74

7�6�2 Removal of the Bent Tube Assembly �� 74

7�6�3 Inspection of Bent Tube Assembly �� 75

�� 74

�� 71

SuperLite® 17B

7�6�4 Installation of the Bent Tube Assembly�� 75

7.7 Hose Assembly (SL-17A only) �� 76

7�7�1 Hose Assembly Removal �� 76 7�7�2 Hose Assembly Inspection “A” style Side Block �� 76 7�7�3 O-Ring Replacement �� 76 7�7�4 Hose Assembly Replacement �� 76 7�8�2 SuperFlow® Demand Regulator Test for Correct Adjustment, Fully Assembled ��77

7.8 SuperFlow® Demand Regulator �� 77

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

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

�� 79

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

7.8.10.1 Important Notes on Regulator Adjustment �� 92

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

7.9 Oral Nasal �� 96

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

7.10 Quad-Valve™ Exhaust Assembly ��98

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

7.11 Water Dump Exhaust Body �� 103

7�11�1 Water Dump Valve Removal �� 103 7�11�2 Water Dump Valve Replacement �� 103 7�11�3 Water Dump Valve Body Removal �� 103 7�11�4 Water Dump Valve Body Remounting �� 103

7.12 Reinstalling the Quad-Valve™ Exhaust Assembly

�� 105

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

7.14 Double Exhaust Whisker

�� 108

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

7.15 Tri-Valve Exhaust Whisker �� 110

7�15�1 Demand Regulator Assembly Removal �� 110 7�15�2 Replacing the Regulator Exhaust Valve �� 110

SuperLite® 17B

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

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

7.16 Overpressure Relief / Bleed Valve Overhaul Procedures �� 114

7�12�1 Overpressure Relief Valve �� 114

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

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

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

Chapter 8 Corrective Maintenance �� 117

8.1 General

8.2 Yoke/Neck Clamp Assembly and Helmet Shell Inspection

8.3 Nose Block Assembly �� 119

8�3�1 Nose Block Assembly Removal �� 119

8�3�2 Nose Block Device Replacement �� 120

8.4 Handle and Weights

8�4�1 Handle Removal �� 121

8�4�2 Handle Replacement �� 122

8�4�3 Weight Removal �� 123

8�4�4 Weight Replacement �� 123

8.5 Chin Strap and Yoke Strap �� 125

8�5�1 Chin Strap Removal �� 125

8�5�2 Chin Strap Replacement �� 125

8�5�3 Removal of the Yoke Strap �� 126

8�5�4 Replacement of the Yoke Strap �� 126

8.6 Alignment Sleeve �� 128

8�6�1 Sleeve Removal and Inspection �� 128

8�6�2 Sleeve Replacement �� 128

8.7 Port Retainer �� 129

8.8 Face Port �� 129

8�8�1 General �� 129

8�8�2 Face Port and Nose Block Device Removal �� 129

8�8�3 Face Port and Nose Block Replacement �� 130

8�8�4 Special Note Regarding Ports �� 132

8.9 Communications System �� 133

8�9�1 General �� 133

8�9�2 Earphone Inspection �� 133

8�9�3 Microphone Removal and Replacement �� 134

8�9�4 Earphone Removal and Replacement �� 135

8�9�5 Waterproof Connector �� 135

8�9�6 Communications Posts �� 137

8.10 Neck Clamp/Yoke Assembly

8�10�1 Yoke �� 138

�� 117

�� 121

8.9.5.1 Connector Removal �� 135

8.9.5.2 Connector Replacement �� 136

8.9.6.1 Communications Post Removal �� 137

8.9.6.2 Communications Post Replacement �� 137

�� 138

8.10.1.1 Yoke Removal and Disassembly �� 138

8.10.1.2 Yoke Replacement and Reassembly �� 140

SuperLite® 17B

8�10�2 Latch Catch Assembly �� 140

8.10.2.1 Latch Catch Mechanism Disassembly �� 140

8.10.2.2 Latch Catch Mechanism Reassembly �� 141

8�10�3 Neck Clamp Assembly �� 141

8.10.3.1 Neck Clamp Assembly Adjustment /Inspection �� 141

8�10�4 Neck Dam �� 143

8.10.4.1 Neck Dam Replacement �� 143 Pre-84 and Cold Water Type Neck Dam �� 144 Installation �� 144

8.10.4.2 Four Hole Method of Attaching Neck Dam to Hinge Tab �� 145

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

8.10.4.4 Drawstring Type Neck Dam Installation �� 146

8.11 O-Ring Seal Replacement �� 148

8.12 Head Cushion Foam Replacement �� 148

Chapter 9 Accessories �� 149

9.1 Introduction �� 149

9.2 Hot Water Shroud General�� 149

9�2�1 Installation of the Hot Water Shroud �� 149

9.3 Low Pressure Inator Hose Installation on the B Sideblock �� 151

9.4 Weld Lens & Weld Shield Assemblies �� 152

9.5 Use of Quick Disconnect �� 154

9.6 Double Exhaust System �� 155

9�6�1 Double Exhaust Kit Installation �� 155

Table of Equivalents �� 159 Appendix 1: Torque Specications �� 160 Note on Torque Specications �� 161

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® and 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

SuperLite® 17B

DANGER

WARNING

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.

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

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

CAUTION

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

If English is not your native language and you have any 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 info@KMDSI.com or Dive Lab Inc. (850) 235-2715 or at Divelab@aol.com

IMPORTANT: A word about this manual. We have tried to make this manual as comprehensive and factual as possible. We reserve the right, however, to make changes at any time, without notice, in prices, colors, materials, equipment, 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. Periodically KMDSI Operations and Maintenance Manuals are reviewed. Any updates/changes will be posted on the KMDSI website and may be downloaded for insertion/correction.

Important Safety Information:This SuperLite® 17B diving helmet is intended for use by trained divers who have successfully completed a recognized training course in surface supplied diving

SuperLite® 17B

WARNING

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

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

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

Read this manual before using or maintaining the helmet, even if you have experience with other diving helmets. If you have purchased the helmet new from a dealer, be sure to send in the warranty registration card so we may keep you informed of any safety notices that affect this product. If you resell or loan this helmet to another diver,

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

This helmet was completely checked and should be ready to dive as it was shipped from the factory. However, it is always the diver’s responsibility to check all the components of the helmet prior to diving.

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

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

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

SuperLite® 17B

WARNING

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

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

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

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

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

Do not use KMDSI masks or helmets in currents exceeding 3.0 knots Use in currents

greater than 3 knots may allow water to enter the exhaust valve, possibly causing regulator ooding. This could lead to drowning.

Surface-supplied diving can be a strenuous activity. The SuperLite®-17B weighs approximately 30 lbs. KMDSI recommends that persons with a previous neck or back injury seek professional medical approval prior to engaging in surface supplied diving operations using the SuperLite®-17B. Use of the SuperLite®-17B with a pre-existing physical/ medical condition may result in death or serious injury.

If you have any questions regarding the use, maintenance, or operation of this helmet, contact KMDSI at (805) 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®, Flourolube, or Krytox®. Lubricants must be used sparingly and should not be mixed with other lubricants.

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

Many countries have 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.

SuperLite® 17B

WARNING

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

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

Always read the Material Safety Data Sheet (MSDS) for any chemical - adhesive, cleaning agent, or lubricant - used on your Kirby Morgan helmet. Some of these chemicals may cause serious bodily injury or death if used improperly or without the proper personal protective equipment.

Whenever KMDSI helmets or masks are used in European Countries, which have adopted the C.E. 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

SuperLite® 17B

STOP!

BEFORE GOING FURTHER-

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

Chapter 1

General Information KMDSI Products

1.1 Introduction

The Kirby Morgan Corporation was started in 1965. The copper and brass “Heavy Gear” or “Standard Dress” helmets were the 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 fty-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 525-620) and common hand tools. Technician training is available through Dive Lab Inc. Information can be obtained on line at www.divelab.com or by telephone at 850-235-2715.

SuperLite® 17B

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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 sur-

passes 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 KMB 18 and KMB 28 are

approved.

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SuperMask M-48

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w/ Scuba Pod

SuperLite® 17B

KMACS-5

w/ No Communications

approved and ™ marked

The SuperMask M-48 is an innovative new design in a full-face mask. It provides the diver with all the comfort of a full-face mask with the convenience of changeable second stage regulators as well as the ability to use a snorkel without having to remove the mask.

The mask is comprised of two major components, the mask frame and the interchangeable lower pod. The removable lower pod is a feature unique to the SuperMask full-face mask. When diving, the pod is easily removed and replaced on the mask, providing the diver the capability to buddy-breathe, snorkel, use an octopus or perform an “in water” gas switch.

With the pod sealed to the mask, the 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.

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

SuperLite® 17B

1.3 Kirby Morgan Diving Helmets

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

There are eight models of Kirby Morgan diving helmets currently in production. They are the SuperLite 17B, (MK-21- U.S. Navy version), SuperLite the SuperLite 37SS, 47, 57, and 77. All are

The SuperLite

®

27, and Kirby Morgan models 37,

®

-17 A/B was 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 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 their head. The helmet is lowered onto the diver’s head with the help of a tender, then the yoke hinge tab is hooked onto the alignment screw on the rear weight. The neck clamp is then slipped onto the helmet and locked. The locking system

-

not only seals the neck dam to the helmet but also secures the front of the yoke, fastening the helmet to the diver’s head.

The SuperLite

®

-17A/B shares many common breath-

ing system parts with all Kirby Morgan helmets and masks. The breathing system was man-tested to 1600 FSW by the University of Pennsylvania and approved by the U.S. Navy for surface-supplied diving to 190 FSW with air and 300 FSW with mixed gas. It surpasses all requirements of all governing agencies and it is approved for commercial diving through out the world.

SuperLite® 17A/B

approved and ™ marked approved and ™ marked

Yoke and Latch Catch

Assembly

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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

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.

SuperLite® 17B

®

SuperLite

27

®

approved and ™ marked

Kirby Morgan 47

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.

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.

approved and ™ marked

The Kirby Morgan 47 offers the ultimate in a high performance breathing regulator. This helmet has an entirely new breathing system, oral nasal mask, and water ejection system. The REX Demand Valve, with it’s fully adjustable balanced piston is a breakthrough design that exceeds the requirements of all government or other testing agencies.

It has the best work-of-breathing performance when compared to ANY other commercial diving helmet. The Kirby Morgan 47 Dive Helmet has been tested and meets or exceeds European CE requirements and is fully commercially rated. In all other respects, this helmet is nearly identical to the Kirby Morgan 37.

SuperLite® 17B

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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 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.

• 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.

approved and ™ marked

The Kirby Morgan 37SS features an all stainless steel shell, as well as a stainless sideblock, helmet ring, bent tube, handle, and other key components. The SuperFlow

®

350 is standard on this helmet.

SuperLite® 17B

The Kirby Morgan 37SS features a quick change communications module, available with either bare wire posts or a waterproof connector, and allows for easy, 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

SuperLite® 17B

WARNING

CAUTION

WARNING

Chapter 2

®

Description & Operational Specications - SuperLite

This manual is our effort to explain the operation, maintenance and use of the SL 17. We do

not herein make any effort to teach the principles of diving. It is our assumption the reader is a qualied diver. We highly recommend that all divers should train under controlled conditions, in the use of any commercial diving helmet that they have not previously used, or trained in, prior

to use on the job.

-17B

This section includes a detailed description of the SuperLite

®

-17 as well as important operational

specications.

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 Certication

The helmet has been tested and conforms to the performance requirements as set forth in Annex II of Directive 89/686/EEC and, as far as applicable, the EN 250:2000, EN 250/A1:2006 and EN 153331:2008 (class B). It is fully CE marked with demand regulator SuperFlow and P/N 510-747.

Category of PPE: III

®

and oral nasals P/N 510-690

2.2.1. CE Marking

On the frame of the helmet the CE mark is 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 year of production;

5. CE marking:

;

6. number of notied body.

The user cannot:

• remove the mark from the frame of the

helmet;

• modif y or count er feit the da ta r eported

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 be 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.

SuperLite® 17B

DANGER

WARNING

2.2.2. Notied 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 Product Specications

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

Never use aeros ol-pr opell e d s prays n ear the fac e p or t of a ny Kir by Morga n d iving 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.

®

, Krytox®, Tribolube® and

®

111.

2.5 Cage Code

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

2.6 Operational Specications & Limitations

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

Every model of KMDSI helmets and masks undergo extensive type testing to fully document the performance capability and required supply pressures when using various umbilical and pressure combinations. All users should take the time to become knowledgeable on supply requirements to insure proper performance and for the comfort and safety of the diver.

The required supply pressures for the SL-17 equipped with the SuperFlow appropriate supply pressure tables in Appendix 3.

The supply pressures listed in the supply tables were derived by breathing simulator trials. There are two tables used for the SuperFlow regulators. It is important that users understand how to use the tables. For further information on supply requirements for the SL-17 or any Kirby Morgan helmet or mask check the Kirby Morgan website at www.kirbymorgan.com.

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

®

350 regulators are listed in the

®

and SuperFlow® 350

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

2.4 Regulator Performance

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

®

-17

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

resulting in serious injury.

Decompression diving always involves the

DANGER

WARNING

risk of decompression sickness. Omitted decompression due to a loss of the breath-

ing gas supply or other accidents can cause seri ous in jury or death . U se of a SL 17 c a nnot prevent this type of injury.

It is important for the user/diver to take excessive currents into consideration. The Quad-Valve™ Exhaust PN#525-759 is now

standard on the SuperLite 17B. Unlike the old latex double exhaust, the quad system

is not limited to a maximum depth of 150 FSW (46 msw) due to exhalation pressure.

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

SuperLite® 17B

The umbilical assembly should be composed of good quality diving hose that meets industry standards. Generally, gas hose will be married to the communications wire, pneumofathometer hose, and strength member in a manner that will allow the strength member to receive all the strain. There are also good quality umbilicals available that are assembled at the factory using a twisted method which does not require marrying.

Regardless of the system used, the umbilical is the diver’s life line and should always be of excellent quality and maintained carefully.

Gas systems used to supply Kirby Morgan

helmets and masks must be capable of supplying gas to the diver at the required pressure and ow rates as stated in the operational specications. The use of unregulated

gas sources is extremely dangerous.

NOTE The Hot Water Shroud (Part #525-100) in conjunction with hot water to the diver should be used whenever diving operations are conducted using HEO

at water temperatures less than 60°F

2

(15.56°C) for the comfort of the diver. KMDSI further recommends that the shroud be used in conjunction with hot water to the diver whenever diving operations are conducted using air or mixed gas, in waters colder than 33°F (1°C) to reduce the possibility of demand regulator icing. NOTE: Usually the greatest danger of demand regulator icing will be encountered on deck when the surrounding air temperature is less than 32°F (0°C). This effect is primarily due to the refrigeration effect of breathing air pressure reduction, and the addition of moisture from the divers exhalation coming in contact with the topside air temperature. If diving where the water temperature is 33°F (1°C) or warmer but the topside air temperature is below freezing, (32°F (0°C) icing of the demand regulator is possible. To help eliminate the possibility of freezing on the surface, warm water should be run over the exterior of the demand regulator prior to water entry, if the hot water system is not used.

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

The use of standard SCUBA type regulators

is unacceptable, as there are no provisions for adjusting the intermediate pressure to

the diver. Only proven systems that allow for varying the gas supply pressure to the diver

should be used for umbilical diving.

2.7 Helmet Features

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

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

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

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

®

adjustable demand regulator

SuperLite® 17B

WARNING

Port whisker wing

The Quad- Valve™ Exhaust is standard

equipment and recommended for

contaminated water diving.

Quad exhaust cover

Whisker clamp

Starboard whisker wing

Exhaust body

Exhaust valve

Whisker exhaust valve insert

Exhaust main body

Exhaust valve

The SL 17 is congured to receive the umbilical over the shoulder.

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

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

Before attempting any diving in any type

of contaminated water, a complete diving and topside course in hazardous materials emergencies should be completed. The divers and the topside team must

be properly trained and have the proper safety equipment. All helmets and suits

can leak water under certain conditions. Divers should use extreme caution when diving in contaminated waters. For more information see the book “Diving in High-

Risk Envir onments” by Steven M. Barsk y.

When diving in h eavy curren t ( i.e. exce ed-

CAUTION

ing 3 knots) the single exhaust system on all KMDSI masks/helmets could allow water to enter, due to turbulence/eddy-

ing. It is important for the user/diver to take excessive currents into consider-

ation. The Quad-Valve™ Exhaust system

will help prevent water intrusion when

diving in heavy currents. Unlike the old

double exhaust, the Quad-Valve™ does not limit the diving depth.

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

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

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

• the face port and retainer ring

• basic communications components

• the oral nasal mask

• the nose block device

• the air train

• most demand regulator components

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

Each step of the manufacturing process is carefully controlled to assure the customer of a high quality,

SuperLite® 17B

durable helmet that will function properly. The following is a general description of the features of the SL 17.

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

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

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

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

2.8 General Description

2.8.1 Helmet Shell

The helmet shell is fabricated of noncorrosive, rigid 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.

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 component.

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

SuperLite® 17B

Defog Free Flow Valve Knob

Helmet Shell

Rear Weight

Sideblock

EGS Valve

Handle

Port Retainer

Oral Nasal Mask

Equalization Device

Non-Return Valve

Weight

Neck Dam

Neck Clamp Assembly

Quad-Valve™ Exhaust

(standard on all Kirby Morgan 37

helmets from 2005 on)

Regulator Adjustment Knob

Purge Button

The SuperLite® 17B helmet

Latch Catch Mechanism

A

R

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Y

E

L

D

L

A

I

-

C

R

E

M

O

C

D

E

T

S

E

T

B

A

P

R

O

F

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S

I

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A

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I

N

G

L

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V

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™

SuperLite® 17B

WARNING

Adjustment knob

Regulator body

Diaphragm

Cover

Clamp

Inlet valve

Adjustment shaft

Packing nut

Piston

Spacer

Roller lever

Spacer

Nut

Inlet nipple “B”

Retaining pin

Spring

Washer

Inlet nipple “A”

Retaining clip

Jam Nut

Exhaust Valve

Washer

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

Gas Flow To Air Train

Main Gas Supply

Gas Flow To Regulator

Auxiliary L.P. Port

The one way v alve m u st be t este d d aily, prior to the commencement of diving operations.

Fa ilure of o ne way valve could ca use ser ious injury or death. Follow the procedures for

testing the valve in this manual.

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

Returning to the side block assembly: the other passage for gas is to the demand regulator. It goes to a bent tube assembly that connects to the inlet nipple of the demand regulator. The 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 SuperFlow

®

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

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

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

regarding appropriate supply pressures.

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

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 of the faceplate that forms from the diver’s warm breath.

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

regulator malfunctions.

The SuperFlow® Demand Regulator

SuperLite® 17B

DANGER

CAUTION

Never connect the main gas supply hose

from the diving station/umbilical to the emer-

gency valve. There is no one way valve in the em ergen cy valv e. If th i s mistake is made , any break in the supply hose could possibly

result in a “squeeze”.

This could result in serious injury or death.

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

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

The regulator adjustment knob should be adjusted to the easiest breathing setting at all times. Adjusting the regulator fur-

ther in th an necess a r y to keep fr om free-

owing increases breathing resistance.

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. When using a dry suit ination hose, 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.

Diving a KMDSI helmet or BandMask

®

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.

Kirby Morgan SuperLite 17B Operation And Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual