Kirby 47 User's Manual
Contents
1. training course in surface supplied diving X Copyright 1970 2007 Kirby Morgan Dive Systems Inc All rights reserved Document 070604002 Kirby Morgan 47 Follow all the instructions in this manual carefully and heed all safety precautions Im proper use of this diving helmet could result in serious injury or death WARNING Kirby Morgan Dive Systems Inc KMDSI warns all divers who use Kirby Morgan div ing helmets or masks to be sure to use only KMDSI original parts from a KMDSI au thorized 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 A WARNING Diving in waters that are chemically biologically or radiologically contaminated is ex tremely 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 affect2. Germicidal Cleaning Solutions and Procedure 68 6 4 Daily Maintenance 69 6 5 Monthly Maintenance or between jobs 70 6 5 1 Locking Collar Assembly amp Helmet Ring 70 6 5 2 Neck Dam Ring Assembly 70 6 5 3 Head Cushion and Chin Cushion 71 6 5 4 Communications Inspection 71 Vi Copyright 1970 2007 Kirby Morgan Dive Systems Inc All rights reserved Document 070604002 Kirby Morgan 47 6 5 5 Lubricate Nose Block O Rings 71 6 6 REX Demand Regulator amp Exhaust System Post Dive Cleaning amp Sanitizing 72 6 6 1 Post Dive Disassembly 72 6 6 2 Sanitizing 73 6 6 3 Post Dive Reassembly 73 Chapter 7 0 Breathing System Maintenance and Repairs 76 7 1 Introduction 76 7 2 Torque Values 76 7 3 One Way Valve 76 7 3 1 Disassembly Of The One Way Valve 76 7 3 2 Reassembly of the One Way Valve 77 7 4 Side Block Assembly 79 7 4 1 General 79 7 4 2 Removal of the Bent Tube 79 7 4 3 Separating the Side Block Assembly from the Helmet Shell 79 7 4 4 Side Block Assembly Replacement 81 7 5 Defogger Valve 83 7 5 1 Disassembly of the Defogger Valve 83 7 5 2 Cleaning and Lubricating 83 7 5 3 Reassembly of the Defogger Valve 84 7 6 Emergency Valve Assembly 85 7 6 1 Disassembly of the Emergency Valve 85 7 6 2 Cleaning and Lubricating 85 7 6 3 Reassembly of Emergency Valve 86 7 7 Bent Tube Assembly 88 7 7 1 General 88 7 7 2 Removal of the Bent Tube Assembly 88 7 7 3 Inspection of Bent Tube Assembly 88 7 7 4 Reinstallation of the Bent Tube Assembly 89 7 8 De
3. Kirby Morgan 47 Helmet 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 May 2007 Future changes will be shown on page III and the changed pages will carry the date of change Previous manuals may not reflect 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 gov ernment and non government testing agencies throughout the world It is approved for use on all commercial and military work underwater Only Kirby Morgan masks and helmets have achieved the CR Commercially Rated mark the highest United States of America rating SuperLite Band Mask KMB KMB BandMask Kirby Morgan DSI Diving Systems International EXO SuperFlow REX SuperMask the color yellow on diving helmets and masks and DECA are all
4. SI 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 appropri ate KMDSI manual In addition the user is responsible to ensure that all product updates as recommended by KMDSI have been performed 3 Unauthorized modifications 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 war ranty claims will be honored without a satisfactorily completed warranty card on file at KMDSI Il Copyright 1970 2007 Kirby Morgan Dive Systems Inc All rights reserved Document 070604002 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
5. 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 Description of Change Page Number Copyright 1970 2007 Kirby Morgan Dive Systems Inc All rights reserved Document 070604002 Ill Kirby Morgan 47 Z WARNING Diving with compressed breathing gas is a hazardous activity Even if you do everything right there is always the potential for serious injury or death No one piece of diving equipment can prevent the possibility that you may be injured or killed any time you enter the water 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 Copyright 1970 2007 Kirby Morgan Dive Systems Inc All rights reserved Document 070604002 Contents Definition of Signal Words Used in this Manual Chapter 1 0 General Information KMDSI Products 1 1 Introduction 1 2 Full Face Masks and Manifolds 1 3 Kirby Morgan Diving Helmets Chapter 2 Description amp Operational Specifications Kirby Morgan 47 2 1 Product Specifications 2 2 Regulator Performance 2 2 1 REX Regulator 2 2 2 Minimum Operating Temperature 2 3 Cage Code 2 4 CR Standards 2 5 Operational Sp
6. c All rights reserved Document 070604002 Chapter 9 0 Accessories for the Kirby Morgan 47 9 1 Introduction 9 2 Low Pressure Inflator Hose 9 2 1 Installation of the Low Pressure Inflator Hose 9 3 Weld Lens Assembly 9 3 1 Weld Lens Assembly Installation 9 4 Weld Shield Assembly 9 4 1 Weld Shield Assembly Installation 9 5 Use of Quick Disconnect Table of Equivalents Appendix 1 Torque Specifications Note on Torque Specifications Checklist Maintenance and Pre Dive Inspections Copyright 1970 2007 Kirby Morgan Dive Systems Inc All rights reserved Document 070604002 Kirby Morgan 47 140 140 140 140 141 141 142 142 142 143 144 145 145 Kirby Morgan 47 Definition of Signal Words Used in this Manual For your protection pay particular attention to items identified by signal words in this manual These terms are identified as CAUTION WARNING AND DANGER It is especially important for you to read and understand these sections A DANGER This word indicates an imminently hazardous situation which if not avoided could re sult in death or serious injury WARNING This word indicates a potentially hazardous situation which if not avoided could result in death or serious injury A 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 nativ
7. cian certified in fiberglass repair A log entry should be made in the hel met 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 Copyright 1970 2007 Kirby Morgan Dive Systems Inc All rights reserved Document 070604002 XI Kirby Morgan 47 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 WARNING y Kirby Morgan masks and helmets are cleaned and lubricated for oxygen ser H vice when they come from the factory However if the helmet is used with an 4 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 oxy gen If this is not done fires and explosions may result exposing the user to serious personal injury or death Comp
8. ding Ports 120 8 5 5 Port Retainer 120 8 6 Neck Dam 121 8 6 1 Removal of the Neck Dam 121 8 6 2 Neoprene Neck Dam Replacement 121 8 6 3 Latex Neck Dam Replacement 124 8 6 4 Trimming a Latex Neck Seal 125 8 7 Neck Dam Pull Strap 126 8 7 1 Neck Dam Pull Strap Removal 126 8 7 2 Neck Dam Pull Strap Replacement 126 8 8 Chin Strap 126 8 8 1 Chin Strap Removal 126 8 8 2 Chin Strap Replacement 126 8 9 O Ring Seal Replacement 127 8 10 Helmet Ring 128 8 10 1 Helmet Ring Repairs 128 8 11 Sealed Pull Pins 128 8 11 1 Removal of Sealed Pull Pins 128 8 11 2 Replacement of Sealed Pull Pins 128 8 12 Swing Tongue Catch 129 8 12 1 Disassembly of the Swing Tongue Catch 129 8 12 2 Reassembly of the Swing Tongue Catch 130 8 13 Locking Collar 131 8 13 1 Locking Collar Removal 131 8 13 2 Locking Collar Disassembly 132 8 13 3 Locking Collar Reassembly 133 8 14 Head Cushion and Chin Cushion 134 8 14 1 Head Cushion Foam 134 8 14 2 Chin Cushion Foam 134 8 15 Communications System 135 8 15 1 General 135 8 15 2 Earphone Inspection 135 8 15 3 Removal of Communications Assembly 136 8 15 4 Replacement of Communications Assembly 136 8 15 5 Microphone Replacement 136 8 15 6 Earphone Replacement 137 8 15 7 Waterproof Connector 138 8 15 7 1 Connector Removal 138 8 15 7 2 Connector Replacement 138 8 15 8 Communications Posts 138 8 15 8 1 Communications Post Removal 138 8 15 8 2 Communications Post Replacement 139 Vill Copyright 1970 2007 Kirby Morgan Dive Systems In
9. e language and you have any difficulty understanding the language of any warnings as they appear in the manual please have them translated Este um aviso importante Queira mand lo traduzir WARNING Este es un aviso importante Sirvase mandario traducir A WARNING Quest un avviso importante Tradurlo WARNING Ceci est important Veuillez traduire A WARNING Diese Mitteilung ist wichtig Bitte bersetzen 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 specifications 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 find a dealer near you please see the Kirby Morgan web site www kirbymorgan com Periodically KMDSI Operations and Maintenance Manuals are re viewed 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
10. ecifications amp Limitations 2 6 Helmet Features 2 7 General Description 2 7 1 Helmet Shell 2 7 2 Gas Flow Systems 2 7 3 Emergency Gas Supply System EGS 2 7 4 Helmet Attachment to the Diver 2 7 5 Sealing Arrangement 2 7 6 Reducing Carbon Dioxide 2 7 7 Communications 2 7 8 Equalizing the Middle Ear 2 7 9 Face Port or Viewing Lens 2 8 Accessories 2 8 1 Eye Protection for Welding 2 8 2 Helmet Carrying Bag 2 8 3 Special Regulator Tools for REX Regulator Chapter 3 0 Operating Instructions 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 3 4 2 Trimming the Neck Dam 3 4 3 Adjusting the Neck Pad 3 5 Pre Dress In Procedure 3 5 1 Pre Dive Visual Inspection 3 6 Preparing the Helmet for Diving 3 6 1 Clean Face Port 3 6 2 Check Moving Parts 3 6 3 Check Communications 3 6 4 One Way Valve Check 3 7 Emergency Gas System EGS 3 8 Setting Up to Dive 3 8 1 Flushing Out the Umbilical the Helmet 3 8 2 Connecting the Umbilical to the Helmet 3 8 3 Opening the Breathing Gas Supply to the Helmet 3 8 4 Fogging Prevention 3 8 5 Donning The Kirby Morgan Helmet 3 8 6 Testing the Breathing System Copyright 1970 2007 Kirby Morgan Dive Systems Inc All rights reserved Document 070604002 Kirby Morgan 47 Kirby Morgan 47 3 8 7 Sealing Integrity Check 53 3 8 8 Adjust Regulator for Low Work Rates 53 3 9 Removing the Helme
11. mand Regulator amp Exhaust System Overhaul 90 7 8 1 System Disassembly 90 7 9 Cleaning REX Regulator Parts 96 7 9 1 Precautions for Cleaning 96 7 9 2 Cleaning Instructions 96 7 10 REX Regulator Re Assembly 97 7 11 Testing the REX Demand Regulator for Proper Adjustment 105 7 11 1 REX Adjustment Troubleshooting 105 7 12 Oral Nasal Mask 106 7 12 1 Oral Nasal Removal 106 7 12 2 Inspection of Oral Nasal 106 7 12 3 Oral Nasal Replacement 106 7 13 Reinstalling the Regulator on the Helmet 107 7 14 Overpressure Relief Bleed Valve Overhaul Procedures 109 7 14 1 Overpressure Relief Valve 109 7 14 2 Overpressure Relief Valve Disassembly and Cleaning 109 7 14 3 Overpressure Relief Valve Reassembly 110 7 14 4 Overpressure Relief Valve Lift Check Setting 110 Chapter 8 Corrective Maintenance 112 8 1 General 112 8 2 Helmet Shell Inspection 112 8 3 Nose Block Assembly 113 8 3 1 Nose Block Assembly Removal 113 8 3 2 Nose Block Device Replacement 113 Copyright 1970 2007 Kirby Morgan Dive Systems Inc All rights reserved Document 070604002 Vil Kirby Morgan 47 8 4 Handle and Weights 114 8 4 1 Handle Removal 114 8 4 2 Handle Replacement 114 8 4 3 Side Weight Removal 115 8 4 4 Weight Replacement 116 8 4 5 Top Weight Removal 116 8 4 6 Top Weight Replacement 116 8 5 Face Port 117 8 5 1 General 117 8 5 2 Face Port Port Retainer and Nose Block Device Removal 117 8 5 3 Face Port Port Retainer and Nose Block Replacement 118 8 5 4 Special Note Regar
12. onents 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 WARNING 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 appro priate life support systems such as air or gas supplies and support personnel as de scribed 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 fluence 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 WARNING Never use the helmet without first completing all pre dive maintenance and set up pro cedures Z WARNING Do not use KMDSI masks or helmets in currents exceeding 3 0 knots Use in currents greater than 3 knots may allow water to enter the exhaust valve possibly causing regu lator flooding WARNING S
13. registered trademarks of Kirby Morgan Dive Systems Inc Use of these terms to describe products that are not manufactured by KMDSI is not permitted 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 dress protected Copyright 1970 2007 Kirby Morgan Dive Systems Inc All rights reserved This manual is made available for the express use of the owner of this Kirby Morgan product No part of this manual may be reproduced stored in any retrieval system or transmitted or used in any form or by any means whether graphic electronic mechanical photocopy or otherwise by technology known or unknown without the prior written permission of Kirby Morgan Dive Systems Inc Document Number 070604002 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 ninety 90 days from date of purchase This warranty covers all metal fiberglass and plastic parts This warranty does NOT cover rubber parts communications components or headliners In addition due to the electrolytic nature of underwater cutting and welding chrome plating cannot be warranted when the diver engages in these activities Should any part become defective contact the nearest authorized KMD
14. s 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 clean ing 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 per sonal protective equipment Copyright 1970 2007 Kirby Morgan Dive Systems Inc All rights reserved Document 070604002 XIII Kirby Morgan 47 Handle Defog free flow valve knob by Helmet shell Port retainer Oral nasal mask Sideblock EGS valve Equalization device Regulator adjustment knob Non retur valve Pull pin Purge button Communications module The Kirby Morgan 47 helmet Rex 3 Exhaust System XIV Copyright 1970 2007 Kirby Morgan Dive Systems Inc All rights reserved Document 070604002
15. t 54 3 10 Diving Procedures 55 3 10 1 Standing By to Dive 55 3 10 2 Attaching the Umbilical to the Harness 55 3 10 3 Diver Dons Helmet 55 3 10 4 Diver Check Gas Flow Systems 55 3 10 5 Communications Check 55 3 10 6 Diver Ready 55 3 10 7 Water Entry and Descent 55 3 11 Emergency Procedures 56 3 11 1 Flooding 56 3 11 2 Inhalation Resistance 56 3 11 3 Gas Flow Stops 56 3 11 4 Demand Regulator Free Flow 57 3 12 Post Dive Procedures 58 3 12 1 Removing the Equipment 58 3 12 2 Removing the Helmet 58 3 12 3 Storage of the Helmet Between Dives 58 Chapter 4 0 Troubleshooting 59 4 1 General 59 4 2 Communication Malfunction 59 4 3 One Way Valve Malfunction 59 4 4 Side Valve Malfunction 60 4 5 Water Leakage Into Helmet 60 4 6 Demand Regulator Malfunction 61 4 7 Emergency Gas Supply Valve 61 Chapter 5 0 Inspection and Maintenance 62 5 1 Daily Maintenance 62 5 2 Monthly Maintenance 62 5 4 Yearly 62 Chapter 6 0 General Preventative Maintenance 63 6 1 Introduction 63 6 2 Required tools Sealing Cleaning Agents Lubrication 63 6 2 1 Component and Parts Cleaning 64 6 2 2 Component and Parts Lubrication 64 6 2 3 Teflon Tape 65 6 2 4 RTV Sealant 65 6 2 5 Thread Locker 65 6 3 General Cleaning amp Inspection Procedures 65 6 3 1 O Ring Removal Inspection Cleaning and Lubrication 66 6 3 2 General Cleaning Guidelines 66 6 3 2 1 Mild Soap Solution for General Cleaning and Leak Detector Use 68 6 3 2 2 Acidic Cleaning Solution and Procedures 68 6 3 2 3
16. 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 WARNING Diving is a life threatening occupation Even if you do everything right you can still be killed or injured None of the models of Kirby Morgan helmets or masks can prevent ac cidents 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 compo nents 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 previ ous 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 cos metic purposes should be first certified free of fiberglass damage by an authorized KMDSI techni
17. urface supplied diving can be a strenuous activity The Kirby Morgan 47 weighs ap proximately 30 Ibs 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 specific 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 equip ment XII Copyright 1970 2007 Kirby Morgan Dive Systems Inc All rights reserved Document 070604002 Kirby Morgan 47 Whenever KMDSI helmets or masks are used in European Countries which have adopted the C E certification pro grams they must only be used with C E certified components Diving operations should only be conducted within the limits of the operational specifications and in accordance with the rules and regulations established by the governing authority in the specific country or geographical location where the diving operations are being conducted If you have any question
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