Communications, Modular (excludes 17B, 17C, MK

Communications, Modular (excludes 17B, 17C, MK
Communications, Modular
Daily Maintenance
Communications, Modular
(excludes 17B, 17C, MK 21 and KMB BandMasks®)
Contents
COM-1
1.1 Daily Maintenance
COM-1
1.2 Monthly Maintenance (or
between jobs) (See Dive Lab
Checklist A2.2)
COM-2
1.3 Communications System
COM-2
1.3.1 General
COM-2
1.3.2 Earphone Inspection
COM-3
1.3.3 Removal of Communications
Assembly
COM-4
1.3.4 Replacement of
Communications Assembly
COM-5
1.3.5 Microphone Replacement
COM-5
1.3.6 Earphone And Wire
1.1 Daily Maintenance
1) Remove the communications assembly from
the helmet so it can dry completely. Remove the
earphone covers from the earphones so they can
dry completely. Clean the microphone with sanitizing solution, rinse it, and allow it to dry.
Assembly Replacement
COM-6
1.3.7 Waterproof Connector
COM-6
Connector Removal
COM-7
Connector Replacement
COM-7
1.3.8 Terminal Connections in the
Waterproof Connector
COM-9
1.3.9 Communications Posts
COM-9
Communications Post Removal
COM-10
Communications Post
Replacement
1.2 Monthly Maintenance (or
between jobs) (See Dive Lab
Checklist A2.2)
Visually inspect the earphones, microphone,
wires, terminals, and communications posts if
installed. Test each component for proper operation. Connect to the deck amplifier and talk back
and forth. Replace any weak earphone or microphone. Open the earphone rubber covers and
remove the protectors. Allow to dry thoroughly.
Replace defective earphones.
Uncover the earphones so they may dry.
© MMXV Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 150429002
COM-1
Communications System
Communications, Modular
1.3 Communications System
1.3.1 General
The communications system in Kirby Morgan
helmets requires regular attention and maintenance for proper function. Clear two way speech
communications between the diver and the surface crew is one of the most important capabilities of surface supplied diving operations.
1.3.2 Earphone Inspection
To inspect the earphones, first remove the head
cushion from the helmet. The earphones can be
carefully pulled out of the retainers in the helmet
shell for inspection and disassembly.
Good communications are vital to your safety.
Regularly inspect the components of the
communications system and replace when necessary.
Waterproof Connector
1) Remove the (clear) cover first and slide it along
the wire to get it out of the way. Remove the earphone protector and then peel back the (black)
rear cover.
Ferrule
Terminal
Packing
Gland
Nut
O-ring
Comm
Module Cover
Microphone
Screw
Earphone
Comm
Module
Nut
Washer
Washer
Nut
O-ring
Comm Post
Comm
Mount Nut
Wiring Harness
Components of the communications system.
COM-2
© MMXV Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 150429002
Communications, Modular
If moisture is detected inside the covers, carefully check the speaker and dry the parts as needed.
Communications System
Three fingers, is all that is required. The module does not need to be tightened excessively to
maintain a proper seal.
NOTE: Excessive torque may cause part failure.
The entire communications assembly can be replaced as follows:
1) Slide the earphones out of the retainers.
Removing the rubber cover from the earphone.
2) Check the wire connections. They should be
solid.
3) Check the mylar diaphragm. If the mylar is
torn or loose, replace the entire unit, see "1.3.6
Earphone And Wire Assembly Replacement" on
page COM-5.
Remove the earphones from the earphone retainers.
2) Pull the microphone out of the oral nasal mask.
Inspect the mylar earphone.
4) If the rubber covers are worn or damaged, replace them.
1.3.3 Removal of Communications
Assembly
Tools Required: None
The communication module and mount nut
should be checked daily for proper installation
and tightness. The best way to check is by simply
loosening the mount nut by hand (Counter clockwise 1/8 to ¼ turn) then retightening by hand.
© MMXV Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 150429002
COM-3
Communications System
Communications, Modular
replaced with a spare assembly for the most rapid turnaround.
The modular communications system
can be rapidly replaced.
1.3.4 Replacement of Communications
Assembly
The microphone must be removed
from the oral nasal mask.
3) Unscrew the communication mount nut on the
outside of the helmet shell.
1) Install the O-ring onto the communications
module.
2) Carefully push the communications module
through the opening in the helmet shell. The
communications posts, or waterproof connector
assembly if present, should be pointed toward
the rear of the helmet.
3) Screw the communication mount nut onto the
communications module. Tighten by hand until
snug against the helmet. NEVER use a wrench
to tighten this part.
B WARNING
The communication mount nut should
never be tightened using a spanner or
other tool. Tightening the mount nut
using a tool will add excessive strain
to the parts and could cause damage
to the module allowing the module to
break free, resulting in flooding of the
helmet which could cause injury or
drowning.
The large plastic communication nut is
removed from the communications module.
4) Push the communications module into the helmet shell interior. Remove the O-ring.
5) The entire communications assembly can be
COM-4
© MMXV Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 150429002
Communications, Modular
Communications System
crophone. Note that the wires must go on separate terminals, just as before.
6) Install the microphone into the oral nasal
mask.
The mount nut must be securely fastened to hold
the com module in position. Hand tighten only.
4) Place the earphones into the earphone retainers.
5) Route the earphone wires so they do not obscure the diver’s vision. The wire for the left
speaker is tucked into the space between the bottom of the oral nasal mask and the helmet shell.
1.3.5 Microphone Replacement
Tools Required:
1/8 inch Flat Blade Attachment on Torque Screwdriver
The entire microphone is replaced the same as
the ear­phones by removing the wire lugs from
the communications module and replacing the
entire unit.
1) Remove the entire communications assembly
as per "1.3.3 Removal of Communications Assembly" on page COM-3.
2) Remove the rubber cover.
3) Remove the screws and washers from the communications module.
4) Lift the terminal lugs out of the communications module. Note the position of the terminal wires.
5) Install the terminals for the replacement mi-
Install the microphone into the oral nasal mask.
1.3.6 Earphone And Wire Assembly
Replacement
NOTE: If only the earphone speaker is damaged,
it can be replaced by removing the tie-wrap inside
of the covers, unscrewing the wire connection and
replacing the necessary components. There is no
need to completely remove the assembly from the
communications module.
Tools Required:
1/8 inch Flat Blade Attachment on Torque Screwdriver
The earphones may be replaced individually if
needed, however, if one is “bad”, the other earphone will probably need to be replaced soon.
1) Remove the entire communications assembly
as per "1.3.3 Removal of Communications Assembly" on page COM-3.
2) Remove the rubber cover of the communications module.
3) Remove the screws and washers from the communications module.
4) Lift the terminal lugs out of the communications module. Note the position of the terminal wires.
© MMXV Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 150429002
COM-5
Communications System
Communications, Modular
5) Install the terminals for the earphones. Note
that the wires must go on separate terminals as
before.
Comm Module
Cover
Screw
1.3.7 Waterproof Connector
Almost all Kirby Morgan helmets are supplied
with modular communications that have either
a waterproof connector or bare wire posts. The
waterproof connector is subject to failure if the
helmet receives rough handling. To replace the
connector use the following procedure.
Comm Module
Nut
Washer
Washer
Nut
Connector Removal
Tools Required:
3/4 inch Open End Wrench
1/8 inch Flat Blade Attachment on Torque Screwdriver
Waterproof Connector
Ferrule
Terminal
Packing
Gland
Nut
O-ring
O-ring
Comm Post
Comm Nut
Wiring Harness
Details of the communications module
1) Remove the communications assembly from
the helmet as per "1.3.3 Removal of Communications Assembly" on page COM-3.
2) Remove the rubber cover.
Details of the waterproof connector assembly.
3) Remove the screws and washers from the communications module.
4) Remove the earphone and microphone wire
terminals from the interior of the communications module.
5) The nut in the packing gland interior of the
communications module will not turn, as it will
Bottom: Red WPC Wire on bottom 505-047
Top:
Black (Left)White (Right) Earphone Assembly Wires P/N 515-018
Bottom: White WPC Wire 505-047
Top:
White Microphone Wires
4-Pin Waterproof
Connector
1. Black WPC Wire 505-047
2. Black Microphone Wires 515-029
1. Green WPC Wire 505-047
2. Black (Right) White (Left) Earphone Assembly Wires 515-019
Microphone
Right Earphone Short
Left Earphone Long
Diagram depicting correct earphone wire insertion for the Waterproof Connector
COM-6
© MMXV Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 150429002
Communications, Modular
jam against the interior of the communications
module. Use the 3/4 inch wrench to unscrew the
waterproof connector.
Communications System
11) Thread the screws into the communications
module.
12) Tighten the screws until snug. Do not overtighten.
13) Install the rubber cover.
1.3.8 Terminal Connections in the
Waterproof Connector
Use a 3/4 inch wrench to unscrew
the waterproof connector.
6) Pull the connector through the module.
Installing the connector assembly nut.
Pull the connector out of the module.
Connector Replacement
7) Insert the new waterproof connector assembly
into the communications module.
Tightening the packing nut.
8) Screw the waterproof connector into the nut.
Tighten until snug.
9) Slip the earphone and microphone wires back
into the module.
10) Place the screws with washers through the
opening on the terminal lugs in the connector
and earphone and microphone.
© MMXV Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 150429002
COM-7
Communications System
Communications, Modular
Installing the green wire.
Installing the red wire.
Installing the black wire.
Installing the red microphone wire.
Installing the white wire.
Installing the white microphone wire.
COM-8
© MMXV Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 150429002
Communications, Modular
Communications System
1) Remove the communications assembly from
the helmet as per "1.3.3 Removal of Communications Assembly" on page COM-3.
2) Remove the rubber cover.
3) Remove the screws and washers from the communications module.
4) Remove the earphone and microphone wire
lugs from the interior of the communications
module.
Installing the right earphone wires.
5) Remove the nuts, the wiring harness and
washers from the communications posts.
6) Remove the communications posts from the
module.
7) Remove all traces of silicone sealant from the
communications module.
Communications Post Replacement
8) Apply fresh RTV (silicone sealant) to the base
of the communications posts.
B CAUTION
Use good ventilation when using
RTV sealant. Fumes
from this material
may irritate your
lungs. Read and
follow the directions
in the MSDS before
using this material.
Installing the left earphone wires.
B CAUTION
Installing the O-ring.
1.3.9 Communications Posts
Communications Post Removal
Wear eye protection when using
RTV sealant. This
material may irritate
your eyes. Read and
follow the directions
in the MSDS before
using this material.
Tools Required;
3/8 inch Open End Wrench
Flat Blade Attachment on Torque Screwdriver
© MMXV Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 150429002
COM-9
Communications System
Communications, Modular
B CAUTION
Wear hand protection when using
RTV sealant. This
material may irritate
your skin. Read and
follow the directions
in the MSDS before
using this material
17) Install the rubber cover.
18) Reinstall the communications assembly into
the helmet shell per "1.3.4 Replacement of Communications Assembly" on page COM-4.
9) Insert the communications posts into the module.
10) Install the washers on the communications
posts, then the wiring harnesses.
11) Screw the nuts on the communications posts
and tighten until snug. Do not overtighten.
Use a wrench to tighten the communication post nuts.
12) Wipe off any excess silicone sealant from the
module.
13) Slip the earphone and microphone wires back
into the module through the slot in the side of the
module.
14) Place the screws with washers through the
opening on the terminal lugs in the earphones,
microphone, and wiring harnesses.
15) Thread the screws into the communications
module.
16) Tighten the screws until snug; do not overtighten.
COM-10
© MMXV Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 150429002
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