KIRBY MORGAN D IVE SYSTEMS, Inc.
D
IV
N
c
n
I
.
K
I
Y MORGA
B
R
ES
YSTEMS,
Operations & Maintenance Manual
for the EXO Original
and EXO Balanced Regulator Full Face Mask
Part #: 100-030
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
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.
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved. This manual is made available for the express use
of 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 # 130418001
EXO Full-Face Mask Manual
CAUTION
KMDSI must have your current address to ensure that you receive all safety notices and
other important information concerning the mask. Please notify KMDSI of any change
of address.
II
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved.
Document #130418001
EXO Full-Face Mask Manual
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.
Change Number
Date
1
4/07
2
3
4
1/08
7/08
11/08
5
6
7
8
9
10
11
03/20/2009
03/24/2010
01/21/2011
04/06/2011
03/22/2012
06/13/2012
04/18/2013
Description of Change
Changed warning format. Added chapter on general maintenance and sanitation.
Renamed photos. Layout in Adobe InDesign. Added additional warning on use in
petroleum environments, and avoidance of use of chemical thread lockers.
Added new information on compressor supply pressures for low-pressure systems.
New photographs of EXO-BR. Updated drawings
Changed regulator adjustment procedure. New pressure range for EXO regulators
specified 135-150 p.s.i.g. Added recommendation for locking sleeve quick disconnect fitting. Regulator mount nut should be tightened to 100 inch pounds.
Table of contents redesign.
Updated chapter 1 and copyright.
Updated warranty information and table of equivalents
Updated earphones throughout manual
Added CE certification info
Update copyright date to roman numerals
Updated overpressure relief valve torque specs, verbiage and "head protector" to
"hard shell"
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved.
Document #130418001
III
EXO Full-Face Mask Manual
Table Of Contents
Record Of Changes � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � III
About this Manual � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � VII
Definitions of Signal Words Used in this Manual � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � VII
Warranty Information � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � X
Chapter 1 General Information KMDSI Products� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 1
1.1 Introduction � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 1
1.2 Full-Face Masks and Manifolds� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 2
1.3 Kirby Morgan Diving Helmets � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4
Chapter 2 Operating Instructions � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 9
2.1 Introduction � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 9
2.2 First Use and Pre-Dive Set-Up � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 9
2.3 Pre Dress-in Procedure � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 9
2.4 Visual Inspection � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 9
2.5 Clean Face Port � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 9
2.6 Adjusting the Equalizer EXO Standard or BR� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 10
2.7 Checking Regulator Functions & Preparing the EXO for Use In SCUBA Mode.� � � � � � � � � � 11
2.8 Test the Regulator � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 12
2.9 Wireless Communications � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 12
2.10 Using the EXO in the Surface-Supplied Mode � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 13
2.11 Testing the Manifold Block � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 14
2.11.1 Testing the One-Way Valve � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 14
2.11.2 Testing the Emergency Valve � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 14
2.12 Diver’s Harness � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 15
2.13 Installing the Manifold Block on the Diver’s Harness� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 15
2.14 Bail-Out Bottle (Emergency Air Supply) � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 16
2.15 First Stage Regulator � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 16
2.16 Over-Pressure Relief Valve � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 17
2.17 Configuring Your Emergency Gas System� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 18
2.18 Connecting the Hoses to the Manifold Block � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 20
2.19 Use of Quick-Disconnect� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 20
2.20 Connecting the Umbilical to the Mask � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 21
2.21 Opening the Breathing Gas Supply to the Mask � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 22
2.22 Fogging Prevention � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 22
2.23 Proper Hood Fit � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 23
2.24 Recommendations for Donning and Removing � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 24
2.25 Donning the EXO Mask� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 25
2.26 Removal of the EXO Mask � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 26
Chapter 3 Diving With The EXO Full-Face Mask � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 27
3.1 Introduction � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 27
3.2 Water Entry � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 27
3.3 Regulator Adjustment � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 27
3.4 Spider Adjustment � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 28
3.5 Purging the Mask� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 28
IV
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved.
Document #130418001
EXO Full-Face Mask Manual
3.6 Procedures to Follow for Loss of Breathing Gas � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 29
Chapter 4 Post Dive Procedures And General Maintenance � � � � � � � � � � � � � � � � � 31
4.1 Introduction � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 31
4.2 Required tools, Sealing, Cleaning Agents, Lubrication � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 31
4.3 Component and Parts Cleaning � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 31
4.3.1 Component and Parts Lubrication � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 31
4.4 Disconnecting the Mask from the Diving System � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 32
4.5 Daily Maintenance � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 33
4.6 Inspection Procedures � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 34
4.7 General Cleaning Guidelines � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 36
4.7.1 Mild Soap Solution for General Cleaning and Leak Detector Use � � � � � � � � � � � � � � � � � � � � � � � � � � 36
4.7.2 Acidic Cleaning Solution and Procedures � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 36
4.7.3 Germicidal Cleaning Solutions and Procedure � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 36
4.8 Communications Inspection � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 38
4.9 Reassembling the Mask After Cleaning � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 38
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5.1 General Information � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 39
5.1.1 Special Regulator Tools � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 39
5.2 Original and Standard EXO Regulator Disassembly � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 40
5.3 Original and Standard EXO Rebuild � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 43
5.4 EXO Balanced Regulator Disassembly� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 44
5.5 EXO-BR Regulator Reassembly � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 47
5.6 Regulator Assembly Removal and Installation � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 50
5.6.1 Regulator Assembly Removal� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 50
5.6.2 Regulator Assembly Installation � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 52
5.7 EXO Regulator Adjustment � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 54
5.8 Manifold Block Maintenance � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 56
5.8.1 Daily Maintenance � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 56
5.8.2 Post Dive Procedures � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 56
5.8.3 Annual Overhaul of the Manifold Block Assembly� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 56
5.8.3.1 Disassembly Of Manifold Block � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 56
5.8.3.2 Disassembly and Cleaning of the One Way Valve. � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 57
5.8.3.3 Reassembly of the One Way Valve � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 57
5.8.3.4 Disassembly of the Emergency Gas Supply Valve� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 59
5.8.3.5 Cleaning and Lubricating the Emergency Gas Supply Valve � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 59
5.8.3.6 Reassembly of Emergency Gas Supply Valve � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 59
5.9 Overpressure Relief / Bleed Valve Overhaul Procedures� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 61
5.9.1 Overpressure Relief Valve General � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 61
5.9.2 Overpressure Relief Valve Disassembly and Cleaning� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 61
5.9.3 Overpressure Relief Valve Reassembly � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 62
5.9.4 Overpressure Relief Valve Lift Check/Setting � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 62
Chapter 6 Frame And Lens Repairs � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 65
6.1 General Information � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 65
6.2 Lens Replacement � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 65
6.2.1 Lens Removal � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 65
6.2.2 Lens Installation � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 66
6.3 Buckle Replacement � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 70
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved.
Document #130418001
V
EXO Full-Face Mask Manual
6.3.1 Buckle Removal � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 70
6.3.2 Buckle Installation � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 70
6.4 Replacing the Face Seal or Frame� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 72
6.4.1 Face Seal Removal� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 72
6.4.2 Face Seal Installation � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 72
Chapter 7 Communications� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 73
7.1 Bare Wire Binding Posts � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 73
7.2 Waterproof Connector (WPC) � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 73
7.3 Wireless Communications � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 75
7.4 Removing the Communications Module � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 76
7.5 Installing the Communications Module � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 77
7.6 Earphone and/or Microphone Removal � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 78
7.7 Earphone and/or Microphone Installation � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 78
7.8 Removing the Waterproof Connector (WPC) � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 79
7.9 Installing the Waterproof Connector (WPC)� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 79
7.10 Removing the Binding Posts� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 79
7.11 Installing the Binding Posts � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 79
7.12 Waterproof Connector (WPC) Assembly Rebuild � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 81
7.13 Waterproof Connector (WPC) Pin Diagrams � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 82
7.14 Post Dive Maintenance � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 82
Appendix Breathing Gas Requirements EXO Balance Regulator FullFace Mask � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 85
8.2 Regulator Performance � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 85
8.2.1 EXO-BR® Regulator � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 85
8.2.2 Minimum Operating Temperature � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 85
8.3 Cage Code � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 85
8.5 CE Approved� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 85
8.5.1 CE Approved � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 85
8.5.2 Notifying Body � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 85
8.4 CR Standards � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 85
8.5.3 Notifying Body � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 86
8.6 Operational Specifications & Limitations for Surface-Supplied Diving � � � � � � � � � � � � � � � � � � � 86
-Umbilical minimum I.D. 3/8” (9.5 mm) of not more than two sections, total length not to
exceed 600 feet (183m).� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 86
8.6.1 Using the EXO-BR Regulator with a Low Pressure Compressor Supply � � � � � � � � � � � � � � � � � � � � 87
8.6.2 Using the EXO-BR Regulator Low-Pressure Compressor Supply Pressure Requirements
Table � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 87
8.6.3 Using a High-Pressure Breathing Gas Supply� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 91
Appendix II EXO Full-Face Mask Transport And Storage � � � � � � � � � � � � � � � � � � � � � � 93
9.1 Helmet Transport And Storage � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 93
9.1.1 One EXO® Full Face Masks � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 93
9.1.2 Two EXO® Full Face Masks � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 94
9.2 Use of Kirby Morgan Original Replacement Parts � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 95
VI
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved.
Document #130418001
EXO Full-Face Mask Manual
About this Manual
The information in this manual is intended to aid the user in optimizing the performance of this mask. This
manual gives reference to using EXO- 26 masks in open circuit scuba mode as well as in surface supplied diving mode. The use of some of this information will often depend on the use of associated support equipment
and operational scenarios. It is not the intention of this manual to teach diving techniques, but rather to give
the user the required technical information to allow Kirby Morgan helmets and masks to be integrated with the
complete diving system.
Definitions 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.
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.
WARNING
This word indicates a potentially hazardous situation which, if not avoided, could result
in death or serious injury.
DANGER
This word indicates an imminently hazardous situation, which if not avoided, will result
in death or serious injury.
If English is not your native language and you have any difficulty understanding the language of any warnings
as they appear in the manual, please have them translated.
WARNING
Este é um aviso importante. Queira mandá-lo traduzir.
WARNING
Este es un aviso importante. Sirvase mandario traducir.
WARNING
Quest è un avviso importante. Tradurlo.
WARNING
Ceci est important. Veuillez traduire.
WARNING
Diese Mitteilung ist wichtig. Bitte übersetzen lassen.
If you have any questions regarding the information in this manual, or the operation of your mask, call KMDSI
at (805) 928-7772
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved.
Document #130418001
VII
EXO Full-Face Mask Manual
IMPORTANT SAFETY INFORMATION
This EXO Full Face Mask is intended for use by trained divers who have successfully completed a recognized training
course in the use of a full face mask, and if used in the surface supplied mode, an approved surface supplied diving course.
Read this manual before using or maintaining the mask, even if you have experience with other full-face masks. If you
have purchased the mask new from a dealer, be sure to send in the warranty registration card so we may keep you in-
WARNING
Follow all the instructions in this manual carefully and heed all safety precautions. Improper use of this diving mask could result in serious injury or death.
WARNING
Kirby Morgan Dive Systems, Inc. (KMDSI) warns all divers who use the EXO Full Face
Mask to use only KMDSI original spare parts from a KMDSI authorized dealer. Although
other parts, O-rings and fittings may not to be manufactured to the same standards
maintained by KMDSI. The use of any spares other than KMDSI original parts may lead
to equipment failure and accidents.
WARNING
Diving in an environment that is chemically, biologically, or radiologically contaminated is
extremely hazardous. Although the EXO Full Face Mask 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.
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 full-face masks can prevent accidents, injuries
or death due to improper training, lack of health, improper supervision, improper job
requirements, improper maintenance or acts of God.
WARNING
DO NOT dive this mask in water containing high concentrations of petroleum based
chemicals. DO NOT use any chemical locking liquids anywhere on the mask. DO NOT
use any type of aerosol sprays on the mask. These chemicals can attack, damage, and
compromise the structural integrity of the plastic parts on the mask . Clean the mask
using only mild soap and water.
formed regarding any safety notices that affect this product. If you resell or loan this mask to another diver, be sure this
manual accompanies the mask and that the person reads and understands the manual.
This manual is supplied to the original purchaser of this mask. If you have any questions about the use of the mask or
you need another copy of this manual, Part Number 100-030, contact KMDSI. If you have any questions regarding the
use, maintenance, or operation of this mask, contact KMDSI at (805) 928-7772
All Kirby Morgan helmets, masks, and low pressure demand regulators must not be used with oxygen mixtures in excess
VIII
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved.
Document #130418001
EXO Full-Face Mask Manual
WARNING
This mask 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 mask prior to diving.
WARNING
The EXO comes from the factory lubricated for oxygen service. If the exo
is to be used for enriched air or oxygen use it must be carefully maintained
and cleaned in accordance with this manual. components requiring Lubrication must be only be lubricated with an oxygen compatible lubricant such
as Christo Lube or Krytox. Any breathing mixture containing an oxygen
content greater than 23% oxygen is considered enriched gas.
of 50% oxygen by volume without first ensuring all low pressure (less than 225 psig, 15.5 bar) gas transporting components have been cleaned for oxygen service. Only oxygen compatible lubricants such as Krytox™ and ChristoLube™
should be used on components requiring lubrication and lubricants should be used sparingly. Never mix different types
of oxygen compatible lubricants. Helmets or masks used primarily for air diving and occasionally for enriched gas use
should be cleaned at more frequent intervals than helmets used for mixed gas diving only.
The Kirby Morgan SuperFlow 1st stage scuba regulator, as well as all Kirby Morgan dive control consoles and highpressure gas components (greater than 225 p.s.i.g., 15.5 bar) should not be used with pure oxygen, Nitrox, or any breathing
gas containing more than 23.5 % oxygen by volume. The first stage is not intended for use with enriched gas mixtures.
WARNING
KMDSI regards the use of any breathing gas mixture greater than 50% oxygen
to be treated as oxygen. This belief is in keeping with the recommendations
set forth by the National Fire Protection Association (NFPA), Compressed
Gas Association (CGA), and the American Society for Testing and Materials
(ASTM).
WARNING
Kirby Morgan “High Pressure Components” (greater than 225 p.s.i.g., 15.5 bar)
must not to be used with pure oxygen, Nitrox, or any breathing gas mixtures
with oxygen content greater than 23.5 % by volume. Using oxygen mixtures
in excess of 23.5 % by volume may lead to a fire or explosion, which could
result in serious injury or death.
WARNING
Any diving helmet, full face mask, regulator, control console or breathing life
support item manufactured or sold by KMDSI must not be used with breathing gas mixtures in excess of 50% oxygen without first ensuring that all gas
transporting components have been cleaned for oxygen service, have oxygen compatible soft goods lubricated with an approved oxygen compatible
lubricant such as Krytox or Christo Lube grease.
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved.
Document #130418001
IX
EXO Full-Face Mask Manual
Operational specifications and limitations for surface supplied air diving and scuba diving for United States
use, and a separate chart for European Union use are presented on Page 4. The information has been separated
because of the differences imposed or required by certain regulating bodies. Whenever Kirby Morgan diving
equipment is used in countries that have adopted CE Certification, only CE certified components can be used
and all components must be part of the tested certified configuration.
It is important for the user to understand the rules, regulations, and philosophy imposed by the governing or
regulating bodies whenever diving operations are being planned or conducted. Diving operations must 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. Technical questions regarding this equipment should be directed to Dive Lab Inc., of 1415
Moylan Road, Panama City Beach Florida. Telephone 850 235-2715, Fax 850-235-0858 e-mail - divelab@aol.com
Warranty Information
Kirby Morgan Dive Systems, Inc. warrants every new mask, helmet, or KMAC Air Control System
to be free from defects in workmanship for a period of three hundred sixty five (365) 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 KMDSI dealer. If there is no
dealer in your area, contact KMDSI directly at (805) 928-7772. You must have a return authorization from KMDSI prior to the return of any item, Upon approval from KMDSI, return the defective part, freight prepaid, to the KMDSI plant. The part will be repaired or replaced at no charge as
deemed necessary by KMDSI.
This warranty becomes null and void if:
1) The product is not registered with KMDSI within ten (10) days of purchase.
2) The product has not been properly serviced and/or maintained according to the appropriate
KMDSI manual. In addition, the user is responsible to ensure that all product updates as
recommended by KMDSI have been performed.
3) Unauthorized 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
warranty claims will be honored without a satisfactorily completed warranty card on file at KMDSI.
X
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved.
Document #130418001
EXO Full-Face Mask Manual
EXO Balanced Regulator Full-Face Mask
Head harness (spider)
Mask frame
Buckle
Lens (viewport)
Regulator
Earphone
Waterproof connector
Inlet adapter
Regulator adjustment knob
Communications module
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved.
Document #130418001
XI
STOP!
BEFORE GOING FURTHER-
EXO Full-Face Mask Manual
This manual will refer to location numbers in specific drawings, or in the exploded view, which is
in the back of this manual. These numbers are called “location” numbers. They are used to find
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 first 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 fifty-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, scientific, 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,
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved.
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.
Document #130418001
1
EXO Full-Face Mask Manual
1.2 Full-Face Masks and Manifolds
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.
LY RATED
™
ST E D C O M M
E
LY RATED
TE
B
GE
AR - DIV
EL
A
B
TE
IAL
-
P
ESSIONAL D
IV
I
marked
RC
F
RO
approved and
™
P
ESSIONAL D
IV
I
KMB® 18 A/B
-
NG
IAL
NG
RC
F
RO
ST E D C O M M
E
The EXO BR (BALANCED REGULATOR) shown
here is designed to meet or exceed recommended
performance goals in both scuba and surface supplied
modes and is
approved. It meets and surpasses
European standards for regulator performance.
™
GE
AR - DIV
EL
A
The KMB 18B Band Mask frame is constructed of
hand laid fiberglass. The head harness is a molded,
strong tear resistant neoprene rubber.
The hood, which attaches to the mask frame with
welded stainless steel bands, provides warmth for the
divers head as well as pockets for the earphones. The
communications connections can be either a male
waterproof plug in type or bare wire posts. Both this
mask and the KMB 28B feature the new Tri-Valve™
Exhaust System.
The KMB 28B Band Mask (not shown) is very similar to the KMB 18, with many parts on the KMB 18B
being interchangeable 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 fiberglass 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.
Both the KMB 18 and KMB 28 are
2
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.
approved.
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved.
Document #130418001
IAL
LY RATED
-
P
B
TE
ESSIONAL D
IV
I
NG
RC
F
RO
ST E D C O M M
E
EXO Full-Face Mask Manual
™
GE
AR - DIV
EL
A
KMACS-5
w/ No Communications
SuperMask M-48
w/ Scuba Pod
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 flexible, 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.
IAL
LY RATED
TE
B
GE
AR - DIV
EL
A
™
P
ESSIONAL D
IV
I
SuperMask M-48
w/ Rebreather pod
-
NG
RC
F
RO
ST E D C O M M
E
The mask may also be used surface supplied when
used with the proper accessories. We are currently
developing several different pod configurations for
both open circuit and rebreather use. For further
information, see the Frequently Asked Questions
(FAQ) area on our web site at www.KirbyMorgan.
com/FullFaceMasks/M48.html.
™
KMACS-5
w/ Communications
The Kirby Morgan Air Control System-5 (KMACS)
is a lightweight, portable control box for use in surface supplied air diving operations. The KMACS-5
controls the diver’s air supply, communications and
monitors the diver’s depth. It allows two divers clear
push-to-talk (two wire) or round robin (four wire)
communications. The KMACS-5 is also available
without communications.
The air supply can be either from a low-pressure
compressor or high-pressure cylinders. The adjustable
first 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 fittings allow for a compressor to
be used as the primary air source.
A complete pneumo system with dual reading gauges
(both US Standard and Metric) is provided for each
diver’s air, as well as a shut-off/bleed system that uses
two high-pressure feed lines which allows changing
of used cylinders without interruption of the diving
operation. Optional shut off valves allow the isolation
of each diver’s air supply.
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
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved.
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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 first 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.
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® 17C the
SuperLite® 27, and Kirby Morgan models 37, 37SS,
47, 57, and 77. All are
marked.
The SuperLite®-17A/B shares many common breathing 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.
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Yoke and Latch Catch
Assembly
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approved and
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The SuperLite®-17 A/B was first developed in 1975
and quickly set a new standard for diving helmet
design. Many large and small commercial diving
companies, military organizations, scientific divers,
and public safety divers are successfully using this
design around the world. This helmet is
marked.
™
marked
Kirby Morgan® 37
approved and
™
marked
Neck Pad and
Sealed Pull Pins.
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved.
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Other features that are common to all Kirby Morgan
helmets include:
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Kirby Morgan® 47
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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.
GE
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The helmet also features the SuperFlow® 350 large
tube adjustable demand regulator. The helmet is
available in the umbilical over the shoulder, “B”
configuration only.
GE
approved and
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 fit and balance seats
the helmet comfortably for long periods of time even
when working in the face down position.
The quick-change communications module, available
with either bare wire posts or a waterproof connector,
allows for easy, efficient maintenance of the helmets
communications.
™
SuperLite® 27®
The helmet comes with the large tube SuperFlow®
350 adjustable demand regulator which provides an
easier breathing gas flow during peak work output.
A quick change communications module is available
with either bare wire posts or a waterproof connector.
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 fit.
NG
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.
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved.
RC
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Face port and retainer ring
Communications components
Oral/nasal mask
Nose block device
Air train defogger
F
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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.
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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 specifically 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.
approved and
™
marked
The Kirby Morgan® 77 represents the first 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 Kirby Morgan® 57 also includes our Quad
Valve™ 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.
The advantages of this all stainless steel helmet include the following:
B WARNING
• No need to remove the handle to remove the port
retainer.
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.
6
• No refinishing required if the surface is scratched
or gouged.
• Faster production of helmets for customer delivery.
• Elimination of threaded inserts for securing the port
retainer to the helmet shell.
• One piece sideblock includes both the free-flow valve
and the Emergency Gas System valve.
• The helmet ring is an integral part of the helmet.
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved.
Document #130418001
EXO Full-Face Mask Manual
®
approved and
™
marked
The Kirby Morgan® 37SS features an all stainless
steel shell, as well as a stainless sideblock, helmet
ring, bent tube, handle, and other key components.
The SuperFlow® 350 is standard on this helmet.
The Kirby Morgan 37SS features a quick change communications module, available with either bare wire
posts or a waterproof connector, and allows for easy,
efficient maintenance of the helmet's communications.
The advantages of this stainless steel helmet include
the following:
• Rugged helmet shell and other components
• No refinishing required if the surface is scratched
or gouged
• Elimination of threaded inserts for securing port
retainer to helmet shell
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved.
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EXO Full-Face Mask Manual
Chapter 2
Operating Instructions
2.1 Introduction
This section provides the manufacturer’s recommendations on how to use the three EXO Full-face Masks.
The use of these diving masks will vary with the type
of diving and environmental conditions. A proper
training program in the use of full-faced masks must
be undertaken prior to diving the mask.
Practice using the mask in a calm, clear body of water (pool) before open water diving. There is a video
available from Team Visions that goes over many of
these basic procedures. The video, Diving With The
EXO-26 Full-face Mask is available from Best Publishing PO Box 30100 Flagstaff Ariz. 86004
Ph 800 468-1055.
2.2 First Use and Pre-Dive Set-Up
When you first receive your EXO Full-face Mask,
carefully unpack it and examine it for any damage
that may have occurred during shipment. Use the
inspection sheet provided to ensure that no damage
has occurred! Read all warning labels & caution tags.
Be sure to complete the enclosed warranty card and
return to KMDSI as soon as possible. Warranty claims
require that a card be on file at KMDSI 10 days after
purchase. Incomplete warranty cards are considered
invalid.
2.3 Pre Dress-in Procedure
Before dressing in for a dive, an inspection of the
mask and all related gear should be made to ensure
everything is in proper working order. This should be
done well in advance of the dive, so any problems or
adjustments can be dealt with. Read and understand
this manual before you dive. Chapter 2 tells you the
basic operating procedures and how to perform the
pre-dive mask inspections and pre-dive regulator
function tests.
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved.
2.4 Visual Inspection
Visually inspect the entire exterior and interior of
the mask.
- The face seal should be in good condition with no
cracks, tears, or punctures.
- The spider (head harness) should be intact. Stretch
the spider and inspect it carefully for signs of cracking or tearing.
- Inspect the face port. It should be clean and clear.
Anti fog solutions should be applied prior to use.
-Check the wiring for the communications, if present.
Make sure the communication module mount nut is
screwed down tight.
-In the EXO Original, inspect the air inlet tube and
make sure it is properly seated on the regulator.
-In the EXO Standard or BR, inspect the oral nasal and
equalizer and make sure they are securely mounted.
If the mask does not have communications installed,
be sure to use a microphone hole plug (320-001) in
the oral nasal.
-Check the regulator assembly to ensure that it is
secured tightly on the mask frame.
-Check the regulator cover to ensure that it is tight on
the regulator body.
-With no air to the mask, screw the regulator adjustment knob all the way out and back in to ensure that
it turns freely.
2.5 Clean Face Port
Remove any sand or debris from the interior of the
mask and face port which may be inhaled or blown
into the divers face, interfering with the diver's vision.
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Under certain conditions, depending upon water temperature, you may find it necessary to prep the mask
lens to keep it from fogging while diving. There are a
number of commercial defoggers available for scuba
diving which work well. Follow the directions on the
label for use.
If no commercial preparation is available it is possible
to use soap. Use a small amount of liquid soap on a
rag and smear a thin film on the inside of the lens.
Do not rinse this film off. Apply the soap just prior to
entering the water.
2.6 Adjusting the Equalizer EXO Standard or BR
There are different height positions that the equalizer
can be adjusted to. Carefully peel the equalizer out of
the wire retainer and reposition it in another one of
the molded grooves in the equalizer. The wire retainer
can also be slightly bent in one direction or another,
up or down, to get the angle of the equalizer just right.
Ensure that the corners of the equalizer grooves are
"snapped" into position on the wire retainer so that it
does not come loose.
The equalizing device can be adjusted to the precise
height and position that you need.
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2.7 Checking Regulator Functions &
Preparing the EXO for Use In SCUBA
Mode.
Attach the low-pressure hose that is supplied with the
mask to the low-pressure (L.P.) port on your 1st stage
regulator and then to the mask. Never connect the hose
or mask to a high pressure (H.P.) port. When attaching
the hose to the regulator ALWAYS USE A BACK UP
WRENCH ON THE NIPPLE TUBE.
The included angle swivel provides more comfort with
at a variety of head positions. KMDSI recommends
always using this attachment.
Prior to attaching your first stage regulator to your tank
be sure the regulator adjustment knob on the mask is
screwed all the way in. This will prevent the regulator
from free flowing when the air is turned on.
CAUTION
If you are not using the inlet angle fitting,
a backup wrench must be used on the hex
fitting of the regulator when tightening.
Otherwise the regulator may come out of
adjustment!
WARNING
A submersible pressure gauge is considered essential for full-face mask scuba
diving. The diver must plan his dive to
avoid running out of air while wearing a
full-face mask. There is no way to safely
buddy breathe underwater, use an octopus rig, or snorkel on the surface while
wearing a the EXO full-face mask. If the
submersible pressure gauge should fail
during the course of a dive, the dive should
be terminated immediately.
Your 1st stage regulator should be equipped with a
submersible pressure gauge. Attach the first stage to
your tank and turn the air on while holding the submersible pressure gauge away from you. Once the air
is on, check the pressure gauge to ensure you have a
full tank.
To check the EXO-standard and BR regulators for
proper function and adjustment, first ensure the demand
regulator adjustment knob is in fully clockwise then
bring up a gas supply at between 135-150 psig. Slowly
back out on the adjustment knob counterclockwise until
a slight free flow develops then adjust in until the free
flow just stops.
At this point lightly depress the purge button, the button should only travel between 1/16th to 1/8” before a
flow is started. If the button travels less than 1/16” or
greater than 1/8” before flow starts the regulator will
need to be adjusted (see chapter 6)
Always use a back-up wrench when attaching or removing a hose to the regulator. Note the angle swivel
in use.
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved.
Higher first stage regulator pressures may cause free
flow, but turning the regulator adjustment knob in should
stop the flow. In the unlikely event there is still flow,
proceed to the regulator adjustment section in Chapter
6 to reset the regulator.
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2.8 Test the Regulator
2.9 Wireless Communications
Any type of an air flow "hiss" should be able to be
adjusted out by using the adjustment knob. If the adjustment knob is adjusted all the way in and the regulator still
hisses, see the regulator adjustment section, Chapter 6.
If you are using wireless communications you should
test the communications by placing the transducers
from both send and receive units in a bucket of water
and speaking into the mask. Communications should
always be tested prior to the diver entering the water.
Loosen all the straps on the spider and hold the mask
on your face. Take a couple of good breaths, breathing
slow and soft at first then hard and fast. The regulator should be operating with the minimal amount of
breathing resistance and no free flowing.
Pressing the purge button should cause a fairly strong
air flow into the mask. If there is no flow when pressing the purge button, or if breathing is difficult, see the
regulator adjustment section in Chapter 6.
There are several manufacturers that produce a wireless
communications unit that can be used with the EXO
Mask. If you are using wireless communications read
and follow all of the manufacturer’s instructions for
your particular unit.
Once you enter the water, the regulator can be adjusted
for a variety of diving conditions and positions just by
turning the adjustment knob in or out.
Your wireless system must not be attached to your
weight belt.
Always test the function of your regulator prior to
entering the water.
12
WARNING
The waterproof case for your wireless
communications unit should only be attached to your scuba backpack, NEVER
to your weight belt. In the event your belt
must be dropped the belt must have a clear
drop path and must not be connected to
any other piece of gear. If this procedure
is not followed the weight belt and wireless electronics case will be attached to
the mask by the connecting wire. This
could cause the mask to flood, leading
to drowning.
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved.
Document #130418001
EXO Full-Face Mask Manual
2.10 Using the EXO in the SurfaceSupplied Mode
At a minimum, if the EXO is to be used for surfacesupplied diving the following systems and components
must be in place and in proper working condition:
If you have not been trained in the proper use of surfacesupplied diving equipment we strongly recommend
that you complete a training course in the use of this
equipment prior to diving in the surface-supplied mode.
1) Air Supply: Either a low-pressure compressor or
high pressure air bottles. (See operating specifications)
Read and understand the Checking Regulator Function
and Preparing The EXO for use in scuba mode section
of this chapter. The basic connecting instructions of
the mask and regulator function tests are the same.
2) Dive Control System: An air management box to
control the flow of air delivered to the diver or divers
(like the KMACS-5 - Kirby Morgan Air Control System - offered by KMDSI).
The one way valve is a very important component. It
prevents the flow of air out of the mask in the event of
a sudden lowering of pressure in the umbilical supply
hose due to an accidental break in the hose or fitting.
Not only would the emergency air be lost if the one way
valve failed (concurrent with a hose or fitting break) but
the diver could be “squeezed”, a very serious accident.
Do not dive in the surface-supplied mode without a
one-way valve.
3) Diver's Umbilical: Hose bundle consisting of air
supply hose, pneumofathometer hose (depth sensing),
communications wire and rope as a strength member.
4) Diver's Manifold Block: A metal block that has a
one way valve that the umbilical attaches to, an emergency valve that the bail out system attaches to and
L.P. ports for attaching the mask hose, dry suit inflators
and other accessories.
5) Bail-out System: Consisting of a harness, bail out
Emergency Valve
Accessory Ports
One Way Valve
KMDSI Manifold Block Assembly
WARNING
The EX0-BR works well in the surface-supplied
mode.
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved.
The EXO Mask is not equipped with a one
way valve (non-return valve) as supplied
from the factory. For surface-supplied diving, the diver must use a manifold block
equipped with a one way valve. Do not
connect the diver's umbilical directly to
the EXO without a one-way (non-return)
valve. In the event of a rupture of the hose,
this can lead to a squeeze, a potentially
fatal accident.
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2.11 Testing the Manifold Block
WARNING
Never dive if the one-way valve is not operating properly. If the hose or breathing
gas/air fitting breaks near the surface a
serious injury could result to the diver’s
lungs and/or eyes. In extreme cases this
could be fatal. The one-way valve must be
tested daily prior to the commencement
of diving operations.
WARNING
The one-way valve must be tested daily,
prior to commencement of diving operations. Failure of the one-way valve could
cause serious injury or death.
WARNING
If the one-way valve or the adapter is loosened this will allow breathing gas to leak
out of the breathing system. This could also
result in a loss of all pressure to the mask,
leaving the diver with nothing to breathe.
bottle, first stage regulator with over pressure relief
valve. This system connects to the emergency valve on
the divers manifold block assembly by a hose.
6) Communications System: Provides hard wire
communication between diver and topside.
Prior to assembling a bail-out system, the one way
valve and emergency valve should be tested for proper
function.
Equipment Needed:
-Manifold Block
-Bail-out bottle
-1st Stage regulator w/octopus and scuba reg
hose attached
-KMACS-5 system with an umbilical supply hose
-Bucket of water
2.11.1 Testing the One-Way Valve
1) With all the accessory holes plugged on the manifold
block, attach the SCUBA type regulator hose from a
first stage regulator that also has an octopus attached,
to the emergency valve on the manifold block assembly.
The octopus will be used for depressurization once the
test is concluded.
2) Connect the first stage to the bail-out bottle, open the
emergency valve all the way, and pressurize the system.
3) Place the pressurized manifold block in a bucket of
water and check the one way valve for leaks. No air
should leak through the one way valve or from anywhere else on the manifold block assembly. If there is
a leak, the one way valve MUST be rebuilt or replaced.
4) As a secondary test, close the emergency valve trapping pressure inside the manifold block assembly and
relieve the pressure on the first stage using the octopus.
Disconnect the hose from the emergency valve.
5) Quickly open the emergency valve by turning the
knob. You should hear the trapped air escaping through
the emergency valve.
2.11.2 Testing the Emergency Valve
1) With all the accessory holes plugged on the manifold
block, attach the umbilical hose to the one way valve.
2) Make sure that the emergency valve is closed all the
way and pressurize the umbilical.
3) Place the pressurized manifold block in a bucket of
water and check the emergency valve for leaks. NO
air should leak through the emergency valve or from
anywhere else on the emergency valve assembly or
manifold block assembly. If there is a leak, the emer-
14
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved.
Document #130418001
EXO Full-Face Mask Manual
gency valve MUST be rebuilt or replaced.
4) Turn the umbilical off and open the emergency valve
to depressurize the system and disconnect the hose.
2.12 Diver’s Harness
The harness provides an attachment point for the
manifold block, tools the diver may use while in the
water, and the "D" ring where the umbilical shackle
connects. The umbilical shackle must connect to the
strength member of the umbilical.
The manifold block attaches to the harness and the
harness is the primary attachment point for the diver’s
umbilical using a snap shackle. Arrange the umbilical
so it attaches to the harness, then to the manifold block
on the harness. This helps eliminate the possibility of
a direct pull on the diver’s mask by top-side.
The harness may also be used to lift an unconscious
diver from the water and should be of sturdy construction. It should be equipped with a jock/crotch strap for
lifting purposes.
2.13 Installing the Manifold Block on
the Diver’s Harness
The manifold block assembly is designed to be worn
on the diver’s harness. Most divers prefer to attach the
manifold block to the right side of the diver’s harness.
The shackle which attaches the umbilical to the harness “D” ring, is usually located on the left side. After
attaching the umbilical to the “D” ring on the left side
of the harness, the umbilical is normally routed behind
the diver’s back to the manifold block.
To attach the manifold to the diver’s harness:
1) Remove one of the screws which holds the mounting
plate on the manifold block body and loosen the other
screw to provide enough clearance for a harness strap.
2) Swing the plate to one side and position the manifold
block on the harness.
3) Swing the plate back into the correct mounting position and thread the screw through the plate and into
the manifold body.
4) Tighten both screws until the harness is compressed
between the manifold and mounting plate holding the
manifold block assembly in place.
Mounting plate
A well designed diver's harness must be rugged.
This harness can be equipped with a crotch strap,
or “jock.”
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved.
Mounting screws
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2.14 Bail-Out Bottle (Emergency Air
Supply)
The diver should always dive with a bail-out bottle
when diving with surface-supplied air, no matter how
experienced the diver or how shallow the water depth.
Should the diver become unexpectedly entangled underwater, or if the top side air supply fails, the bail-out
bottle may provide the few extra minutes of air the
diver needs to deal with the emergency and get to a
safe place.
2.15 First Stage Regulator
The first stage regulator used on the bail-out bottle
should be a high-flow unit. A submersible pressure
gauge must be connected to the regulator to enable
the diver to monitor the status of his bail-out supply.
The size of the bail-out bottle should be determined
by the water depth, the penetration distance, or the
probability of entanglement of the diver. Deeper dives,
or distant penetrations can be made with greater confidence with larger bail-out bottles. Dives which require
the use of a larger bail-out bottle include, but are not
limited to, deep dives and penetration dives.
Use a high-quality first stage for your bail-out system.
The diver should always be equipped with a bail-out
bottle.
The bail-out system must have a submersible pressure
gauge for the diver to monitor the gas supply.
WARNING
Do not dive without a diver worn Emergency Gas System. If the main gas supply
is lost, you will have nothing to breathe
and may drown.
16
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WARNING
WARNING
A standard Scuba submersible pressure
gauge must be connected to the high
pressure port on the first stage so that the
diver can monitor his emergency supply.
2.16 Over-Pressure Relief Valve
When using the EXO, the first stage regulator should
be fitted with an overpressure relief valve. This valve
is included with the EXO-BR and must be installed,
using 20 inch pounds torque, into a low-pressure port on
the first stage regulator. It is also highly recommended
that the valve be used with the EXO Original and EXO
Standard, as well as any surface-supplied diving system,
anytime a bail-out system is used.
The purpose of this valve is to allow the regulator to
bleed off excess pressure should the first stage develop
an internal leak. If the first stage leaks and this valve is
not present, the pressure between the regulator and the
emergency valve on the manifold block could increase
until the hose ruptures. This will cause a complete loss
of the bail-out supply. It could also lead to injury of the
diver due to the whipping action of the hose.
Never dive without an over pressurization relief
valve installed on the EGS regulator (1st stage).
Without the relief valve if the EGS regulator
develops an internal leak, or carries-away,
the full pressure of the EGS cylinder would
be placed on the low-pressure EGS hose and
the Emergency Valve. This could cause the
low-pressure hose to burst resulting in the
complete loss of the EGS system.
WARNING
Decompression diving always involves the
risk of decompression sickness. Omitted
decompression due to loss of gas supply
or other accidents can cause serious injury or death. The use of any Kirby Morgan
full-face mask or helmet cannot prevent
this type of injury.
Order KMDSI Part # 200-017, High Flow Overpressure Relief Valve.
An over-pressure relief valve needs to be
installed on the first stage of the regulator used for bail-out. It must only be
connected to a low-pressure port. Torque
specification for the P/N 200-017 overpressure relief valve is 20 inch pounds.
CAUTION
The first stage regulator must be equipped
with an overpressure relief valve when using the EXO-BR. In the event the first stage
leaks there is no way for the pressure in
the hose attached to the emergency valve
on the manifold block assembly to relieve
itself. The hose may rupture if this occurs
leading to a loss of bail-out supply and
possible personal injury to the diver.
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved.
Document #130418001
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EXO Full-Face Mask Manual
2.17 Configuring Your Emergency Gas System
There are several possible ways to configure your emergency gas system, although at KMDSI we only recommend one method. The configuration we recommend is as follows:
Cylinder Valve Open - EGS Valve on manifold block closed.
This is the only method that we recommend. The advantages of this method are as follows:
• You only need to open one valve to activate your emergency supply.
• There is little danger of flooding your first stage regulator and ruining it.
Possible Emergency Gas Supply Cylinder & EGS Valve Configurations
Configuration
Cylinder Valve
EGS Valve
Advantages/Disadvantages
Configuration 1
(Regulator pressurized)
On
Off
Advantages
• One valve to open
• First stage won’t normally flood
Disadvantages
• If hose or first stage leaks some
or all EGS gas will be lost
Configuration 2*
(No pressure in
regulator)
Off
On
Advantages
• One valve to open
• No loss of gas from cylinder
if hose leaks or regulator leaks
Disadvantages
• First stage will flood and must
be serviced after each day of
diving
Configuration 3*
(Regulator pressurized
then cylinder valve
closed)
On momentarily
then Off
Off
Advantages
• No loss of cylinder gas if
hose or regulator leaks
Disadvantages
• Two valves to open in
emergency
• Slow leak on long dive may
result in flooded 1st stage
• If dive depth exceeds pressure
in first stage, first stage will flood
Configuration 4*
Off
Off
Advantages
• No use of cylinder gas unless
emergency occurs
Disadvantages
• Regulator will flood and need
service daily
• Two valves to open in
emergency
* Requires ability to reach cylinder
valve without difficulty
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There are risks with each method of configuring your
bail-out system. There is a risk that if you have the
bail-out bottle on and the emergency valve on the
helmet closed, that the emergency gas could be lost
if the hose or the first stage itself develops a leak.
However, KMDSI believes that this method poses the
least amount of risk for the diver.
Probably the most serious problem with any of the
other possible configurations is that the first stage will
almost certainly flood if it is not pressurized while you
are underwater.
If the regulator floods and is not promptly serviced,
it will not perform properly when you need it in an
emergency. As a diver, you always must decide how
much risk and what types of risk you are willing to
expose yourself to when you dive. It’s up to each individual to make an informed choice regarding how
to configure your bail-out system. We cannot make
this choice for you.
WARNING
Some divers, keep the EGS gas cylinder
valve shut during the dive. Their rationale
being; in the event of an emergency, they
will simply open the EGS cylinder valve
thus eliminating any EGS air/gas unknowingly being lost due to either a 1st stage
failure or EGS hose failure.
KMDSI strongly recommends never diving
with the EGS cylinder valve shut. The reasoning behind this is twofold. First, with
the EGS cylinder valve open, gas is immediately available in the event of topside
gas interruption via the EGS valve on the
side block simply by opening it. Secondly,
and most importantly, if the EGS regulator (1st stage) is not pressurized, during
descent it is possible that sea water will
leak through the first stage intermediate
circuit and regulator, causing failure of the
EGS regulator and resulting in possible
injury or death.
WARNING
Never connect the main gas supply hose
from the diving control station to the
Emergency Gas valve assembly (EGS).
If this is done there is no one-way valve
protection for the diver in the event of
damage to the umbilical or related equipment. The diver could be exposed to
a serious “squeeze”. This can result in
serious personal injury or death.
WARNING
Always be sure to check the pressure in your bail-out
bottle before you dive.
KMDSI strongly recommends the use of a submersible
pressure gauge with every bail-out system. Not only
does this make it very easy to check your emergency
gas pressure prior to diving, it also allows you, in
most cases, to periodically check the pressure in your
system while you dive. In this way, if you have a leak,
you will probably figure it out and will be able to take
appropriate action.
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved.
Never connect a high-pressure hose
directly to the EGS valve assembly, as
this will transmit the full pressure of the
tank to the manifold block. The manifold
block is not designed for high pressure
and may burst. This may result in severe
personal injury or death.
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2.18 Connecting the Hoses to the
Manifold Block
After the manifold block has been installed on the
diver’s harness you will need to attach the hoses to
route the air supply. Be sure to use the correct size open
end wrenches, not adjustable wrenches, for connecting
the hoses. Adjustable wrenches tend to slip and may
damage the brass fittings used on the hoses.
The manifold block has three low-pressure ports which
will accept a standard U.S. regulator hose and one port
in line with the one way valve, which will accept a
low-pressure high flow hose. A low-pressure high-flow
hose attached to this port and then to the mask will
assure the maximum flow of air to the mask's regulator.
1) Attach the first stage regulator to the bail-out bottle,
but do not turn the air on.
Low-pressure port
bail-out
supply
connects
here
the protective cap from the diver’s end of the umbilical.
Turn the air that supplies the KMACS-5 on.
While holding the open end of the diver’s umbilical
away from you, slowly turn on the air to the umbilical
at the KMACS-5. This action will blow out any water,
dust, or other foreign debris which may have entered
the dive hose. Allow the air to vent from the hose for
at least 15 seconds.
4) Connect the diver’s air supply hose on the umbilical
to the one way valve on the diver’s manifold block assembly. Use the correct size wrenches and always use
a back up wrench. Tighten the fitting only until snug.
Do not overtighten. If too much force is applied to the
fitting it will cause the fittings to deform and leak.
5) Connect the hose that was supplied with the mask
or the low-pressure high flow hose to the appropriate
low-pressure port on the manifold block, then to the
mask. Remember to always use a back up wrench on
the nipple tube when attaching the hose to the regulator on the mask.
2.19 Use of Quick-Disconnect
If you are using the mask for surface-supplied diving, the use of a quick-disconnect fitting with a sleeve
lock is recommended. The quick-disconnect should
be installed on the low-pressure hose that connects
the mask to the manifold block. By using this fitting,
you can separate the mask from the bail-out system to
work on it. The quick disconnect should have locking
sleeve to help prevent accidental separation.
Attachment plate for
the KMDSI Manifold
Blocks
top-side supply
connects here
Non-return valve
2) Screw the hose from the 1st stage onto the emergency valve on the manifold block assembly. Tighten
this fitting.
3) The diver’s umbilical should already be connected
to the topside dive control system at this time. Remove
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The use of a quick-disconnect fitting makes using the
mask much easier for surface-supplied diving.
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Document #130418001
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2.20 Connecting the Umbilical to the
Mask
When you connect the hose to the mask be sure to
use a wrench to hold the adapter, or inlet fitting, and
a second wrench to turn the swivel fitting on the hose.
If this is not done, the adapter will turn inside the one
way valve. If this happens repeatedly the threads will
wear and the valve will need to be replaced.
The connection between the hose and the mask must
only be made up “snug”. Excessive force will deform
and ruin the adapter. A second wrench must be used
when the mask is disconnected as well, otherwise
the adapter and/or the one way valve assembly may
become loose and fail to make a seal.
If you are using waterproof connectors for your communications, take extra care in handling these pieces.
To connect the male and female parts, align the large
pin on the male connector with the yellow mark on the
female connector. Press the two connectors together
until you hear a distinct “pop”. Do not twist the connectors. Tape the two connectors with a bit of electrical
tape to prevent them from pulling apart.
Use two wrenches to connect the umbilical to the bailout manifold. Do the same with the mask.
disconnected.
Do not twist the connectors. Do not pull them apart
by pulling on the thin part of the wires.
To separate the connectors remove the tape, grasp
them at the thickest part, place your thumbs against
each other, and push apart until the connectors are
Be sure to blow out the umbilical to remove any foreign matter,
WARNING
If the one way valve or the adapter is
loosened this will allow breathing gas
to leak out of the breathing system. This
could also result in a loss of all pressure
to the helmet, leaving the diver with nothing to breathe.
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2.21 Opening the Breathing Gas Supply to the Mask
Prior to turning on the air supply for the mask, check to
see that the free flow valve is closed and the regulator
adjustment knob is all the way in.
Slowly bring up the gas pressure to the mask to 150
p.s.i.g. (10.2 bar). Slowly back out on the regulator
Always test the communications before the diver gets
in the water.
Connect the waterproof connectors without twisting
them.
adjustment knob until a slight free flow develops, then
turn the adjustment knob in (clockwise) until the free
flow just stops.
To properly check the breathing system you must
completely don the helmet.
2.22 Fogging Prevention
A thin film of anti-fogging solution may be applied to
the interior of the face port prior to the dive to help
prevent fogging during the dive. A mild liquid dish
washing detergent, or other commercially available
anti-fogging solutions, may be applied with a soft rag
or paper towel to the interior of the port.
You can use electrical tape to secure the waterproof
connectors together.
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A thin film of liquid soap will help to keep the lens
clear.
2.23 Proper Hood Fit
The type of hood that a diver chooses may have direct
bearing on the fit and comfort of the EXO. Excess material on the chin and or jaw will keep the mask from
positioning properly and possibly cause jaw fatigue.
This may also prevent the diver’s face from getting
far enough into the mask for equalizing by pinching
the nose.
When using a dry suit with a latex hood, no adjustment should be needed. However, if the hood covers
too much of your face, it may be necessary to trim a
small amount of rubber off the chin on the hood. If
using a neoprene wet suit hood, you may want to trim
material from the cheek bone downward to under the
front part of the chin.
KMDSI offers a neoprene hood, designed for use with
the EXO mask in colder waters.
Because the face is in a dry air cavity being warmed
by body heat, hood material on the face is not needed
to keep the face warm.
KMDSI makes a hood tailored to the EXO (see the
accessories section of this manual) It must be trimmed
in the same fashion as above. The face seal area is a
thinner two-sided "skin" neoprene for a superior seal.
Note:
A small hole can be punched in the top of the hood to
relieve any build up of air inside. Put the hole or holes
so that they are to either side of the top spider strap.
To properly trim your hood, use the following procedure:
1) With the hood in position on your head, don the
mask as outlined in this chapter.
2) Have someone bend the earphone pockets on the
mask forward, and start marking the hood with a white
china marker at the edge of the face seal, starting at the
cheek bone area, then continue down under the chin
and up the other side to the opposite cheek bone area.
3) Remove the mask and hood. Leave approximately
1/4" extra material from the line marked and trim the
excess material away.
4) Your hood should now work very well with the mask.
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved.
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2.24 Recommendations for Donning
and Removing
A course in the procedures for safe diving with a
full-face mask should be taken and passed before any
type of diving is performed. Practice using the mask
in a calm, clear body of water (pool) before using for
open water diving.
People with narrow faces may need to use the Face
Seal Cushion Kit (Part#325-025) to achieve a good
fit with the mask .
WARNING
The tender must always be present to assist the diver while dressing and whenever
the diver has his mask on his face while
he is out of the water. It is difficult for the
diver to walk while he is dressed in and he
can stumble and fall, resulting in serious
personal injury.
They are allowed free but limited movement to keep
the spider from becoming entangled while the mask
is being handled.
The Face Seal Cushion Kit is a good way to help adjust
the fit of the mask for a person with a narrow face.
Become familiar with the way in which the mask attaches and properly fits your face. Because the face
seal fits the face well when loosely fitted, it is easy to
assume that this is how the mask should be worn. This
assumption is incorrect and can cause negative results
when diving.
Wearing the mask with an incorrect adjustment will not
allow the diver's face to go far enough into the mask.
The air space inside the mask will be excessive, causing buoyancy and possible problems with the fit of the
seal and oral nasal. The main portion of the face seal
is designed to be very flexible and should be stretched
to form a proper seal and be comfortable.
The spider (head harness) and buckles are also important for proper function of the face seal. The spider
legs and rear head cup are all shaped to pull the mask
to the face. The head cup should be placed as low as
possible to reduce jaw fatigue.
The buckles swivel (all except the top buckle) to allow
the spider to find its natural correct position. Do not
try to force the buckles to swivel completely around.
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2.25 Donning the EXO Mask
1) Make sure that all other gear is properly donned, the
air is on, and regulator functions and communications
tests have been done.
2) Make sure all 5 legs of the spider are loosened all
the way.
3) While holding the mask in position by the chin cup,
begin tightening the spider at the bottom straps, but
not all the way.
4) Make sure the cup of the spider is positioned on the
center of the back of your head. It should be low, but
not as low as your neck.
5) Next tighten the top two straps above the temples.
Alternate between top and bottom straps until the face
is positioned properly and snugly into the mask.
The mask is usually the most comfortable when your
nose is partially into the nose pocket. The top center
strap can be tightened slightly to give support to the
mask while standing by for water entry. Once in the
water this top strap may be loosened.
Tighten the lower spider legs first.
Sometimes, if the top strap is too tight and the diver’s
hood fills with air while diving, the hood pushing
against the top strap may cause the mask to lift up on
the face. The spider may be readjusted during a dive.
6) A tender should always be available to assist the
diver to ensure that his mask is donned correctly, his
hoses are routed properly, and to help ensure he does
not fall while walking around on deck.
7) If you are using the EXO hard shell, the special
bracket must be installed prior to donning. The hard
shell is donned after the mask has been donned.
It is the tender's responsibility to tend the diver's hose
and to assist him into and out of the water.
WARNING
Do not dive this mask in water containing concentrations of petroleum based
chemicals. This can cause the mask frame
to fail, causing the mask to flood, leading
to drowning.
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved.
Tighten the upper spider legs next.
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2.26 Removal of the EXO Mask
Removal of the mask is quick and easy.
1) Grasp the bottom of the mask on each side where
the buckles are attached.
2) With your thumbs, push the tabs on the buckles all
the way forward. They will stop traveling once they hit
the buckle caps. Hold the buckles forward.
3) At this point, push the bottom portion of the mask
away from the face as if it were hinged to your forehead. This will release the bottom legs of the spider
and allow quick and easy removal of the mask.
If you are using the EXO hard shell (part #300-010),
the special bracket must be installed prior to donning. The hard shell is donned after the mask has
been donned.
The EXO is easily removed by the diver when necessary.
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Chapter 3
Diving With The EXO Full-Face Mask
3.1 Introduction
This section deals with the different functions and
adjustments that are possible after entry into the water.
Some divers may be satisfied with the fit and function
of the mask as it is set up topside, or it may be easily
adjusted in the water if necessary.
3.2 Water Entry
Many methods of entry into the water are possible
using the EXO-26 or EXO-BR, but a few important
points should be noted. When using the stride entry,
the bottom holes in the exhaust whisker should be
covered to prevent any turbulent water from flowing
past the exhaust valve.
The demand regulator adjustment also serves another
important function, in the unlikely event the mask
should develop a continuous water leak, the diver can
back out on the demand regulator adjustment knob until
the regulator develops a free-flow of gas. The free-flow
of gas will displace any incoming water. The diver then
can abort the dive with both hands free.
If you roll into the water backwards, turn your head to
one side before entering to prevent water from washing
past the face seal to the interior of the mask. In the
event water does enter the mask, keep the regulator
positioned low and simply press the purge button to
remove the water.
WARNING
Do not dive this mask in water containing concentrations of petroleum based
chemicals. This can cause the mask frame
to fail, causing the mask to flood, leading
to drowning.
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved.
The regulator adjustment should always be set for the
maximum ease of breathing.
3.3 Regulator Adjustment
The regulator adjustment knob should always be
adjusted for minimum breathing resistance. Prior to
entering the water, adjust the regulator adjustment knob
out until a slight fee flow develops and then adjust it
in until the free-flow disappears. If diving with scuba
gear no further adjustment should be needed.
If you're diving with surface-supplied gear, the adjustment knob allows the diver to make adjustments for
variations in supply pressures. During the course of
the dive the diver should periodically turn the adjustment knob out (counter clockwise) until the regulator develops a slight free-flow, then turn the knob in
(clockwise) until the regulator free-flow just stops. This
will ensure the diver is always taking advantage of the
best performance for the available delivery pressure.
The regulator adjustment knob can also be used to
compensate when working in various positions and
diving in currents.
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The most noticeable difference in breathing resistance
can be found in a face up position. Resistance increases
with the regulator diaphragm in this position.
If the regulator adjustment knob is adjusted all the way
in and breathing resistance is high, it is sometimes possible for small amounts of water to get past some areas
of the face seal when the mask is not fitted properly.
Any leakage which does occur usually enters in the
temple area.
Backing out on the adjustment knob will decrease the
spring bias tension on the roller lever, allowing the
diaphragm to move the roller lever with less inhalation
effort. This will help prevent water from being drawn
in around the face seal. If leakage still persists, a face
cushion kit is recommended.
3.4 Spider Adjustment
The mask can be repositioned while in the water, by
loosening, repositioning and retightening the spider
legs. The large tabs on each buckle provide this easy
adjustment. It should also be noted that the buckle
travel is limited to allow easy release.
The top leg of the spider can be loosened once in water.
It is possible for the top leg to be too tight which will
cause the mask to be pulled up too far on the face. The
main purpose for the top leg of the spider is to provide
on deck support of the mask. Some divers may prefer
the support of the top leg while in the water, too.
Fine tuning the regulator should be common practice
if you maintain a certain position for any length of
time and then change positions. If you are working
in a face down position and the regulator adjustment
knob is adjusted too far out, the regulator may freeflow. The adjustment knob should be turned in to stop
any excess air flow.
The mask is easily adjusted underwater.
CAUTION
Proper hood fit and spider adjustments
are needed for the mask to fit comfortably
and function correctly.
3.5 Purging the Mask
If the mask is removed and then replaced underwater,
it must be cleared of water (purged). This is done by
simply holding the mask firmly on the face, keeping
the regulator in a low position, and depressing the
purge button. A momentary slight overpressure will
be felt, followed by complete removal of all water
from the interior of the mask. A mask completely
filled with water should take no more than 3 seconds
to completely purge.
In the unlikely event the mask should develop a continuous leak, the diver should maintain a face forward and
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slightly down position, and slowly turn out (counterclockwise) on the demand regulator adjustment knob
until and a steady free-flow of gas develops. The freeflowing gas will displace the water and keep the mask
cavity clear.
The diver should then immediately notify topside (if
equipped with communications) and abort the dive.
3.6 Procedures to Follow for Loss of
Breathing Gas
SCUBA
When diving scuba with a full-face mask it is essential
that the scuba regulator is equipped with an accurate
submersible pressure gauge. If the gas supply is exhausted, there are no provisions for buddy breathing
with the mask on the face.
If the regulator starts breathing hard or quits breathing,
check the air supply. If the gauge indicates air pressure
in the cylinder, back out on the demand regulator adjustment knob until a free-flow is established and abort
the dive. If there is no air in the cylinder, immediately
abort the dive.
Surface-Supplied Mode
If surface-supply gas is interrupted or fails, the diver
should immediately open the emergency valve on the
manifold assembly. If gas is still not restored, the diver
should back out on the demand regulator adjustment
knob (counterclockwise) to establish a steady flow,
notify topside, and abort the dive.
Using the purge button to clear a flooded mask.
WARNING
In the unlikely event the mask should fill
with water, depressing the purge button
should clear the mask. In the event of a
continuing flood, the adjustment knob
should be turned out to cause a regulator
free-flow. The diver should then immediately assume a face down position in the
water to prevent the mask from flooding
again. At this point the diver should exit
the water immediately.
Regardless of the cause, whenever a supply of gas fails
even if it is restored the diver should abort the dive and
the problem should be thoroughly investigate as to the
cause of the failure. Diving should only proceed after
all problems are rectified.
WARNING
If using scuba, use of a steady flow will
rapidly deplete the scuba cylinder. Adjust the free-flow so that the flow of gas
needed to keep the water out is minimal.
Continuous leakage of water into the mask
is not normal. Do not continue a dive if
continuous water leakage is present.
DANGER
Rapid ascent is dangerous. It can lead to air
embolism or decompression sickness. Air/
gas embolism can cause immediate loss of
consciousness and/or death. Even on a no
decompression dive, a rapid ascent may
cause decompression sickness. A diver
must only make a rapid ascent when he is
in immediate danger of death by drowning,
asphyxiation, or some other cause.
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DANGER
Ditching the mask underwater must be
avoided. If the diver ditches the mask
underwater he will not be able to see.
In many instances, if you are diving in
the surface-supplied mode, even if the
air supply is interrupted, topside will be
able to get it back on line quickly. Do not
ditch the mask underwater unless you are
completely out of breathing gas and it is
impossible to return to the surface due to
entanglement of your equipment or similar
circumstances.
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Chapter 4
Post Dive Procedures And General Maintenance
4.1 Introduction
This section covers the preventative maintenance
necessary on the EXO Full-Face Mask. A mask that
is kept clean and in good repair will offer far better
service to the user. These masks are designed for easy
access to all areas for proper inspection and servicing.
4.2 Required tools, Sealing, Cleaning
Agents, Lubrication
All KMDSI helmets and masks are designed with the
professional diver in mind. Most maintenance can be
performed by the diver using common tools and this
manual. There are some repairs however, that must
be accomplished only by KMDSI authorized repair
facilities. This includes fiberglass and helmet neck
ring repairs, face port inserts and sealed pin overhauls.
For technical assistance please telephone your nearest
authorized dealer or call KMDSI at (805) 928-7772.
Every diver should carry sufficient tools and spare
parts to maintain his mask in top working condition.
It is very impor­tant to use wrenches of the correct
size rather than adjustable wrenches when possible.
Adjustable wrenches tend to slip and can round the
edges of soft brass parts.
4.3 Component and Parts Cleaning
The mask and components should only be cleaned
using a mild solution of dish washing soap such as
JOY ™ or Dawn ™ hand dish washing soap.
Parts that have corrosion should
be washed and scrubbed with
a nylon bristle brush and then
soaked in a solution of 50% white
vinegar and water for 30-60 minutes followed by a light brushing
and a good fresh water rinse.
Rubber components should be
cleaned using a mild soapy solution followed by a good rinsing
and air-dried.
Ordinary dish soap is acceptable for cleaning.
DO NOT use hair dryers or high heat to dry the rubber
components, high temperatures will severely reduce
their serviceability. To clean parts heavily encrusted
with salt we recommend a dilute solution of white
vinegar and a toothbrush.
4.3.1 Component and Parts Lubrication
All masks are lubricated at KMDSI with Christo
Lube. Masks used for air diving or diving or with
oxygen mixtures containing less than 50 % oxygen
can be lubricated with food grade silicone such as
Dow corning 111 or equivalent. ChristoLube is the
preferred lubricant.
Special tools are required to do proper maintenance
on the EXO mask.
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved.
Do not use aerosol spray or lubricants. Many aerosol propellants will damage plastic. Avoid lubricant
contact with plastic parts.
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WARNING
Do not used any
type of chemical
locking solutions,
such as Loctite®,
on this mask. They
can at t ack and
severely damage
the mask frame.
This can cause the
frame to fail unexpectedly, causing flooding of the mask and drowning.
4.4 Disconnecting the Mask from the
Diving System
To disconnect the mask from the surface-supplied
system:
1) Disconnect the mask from the diving hose and EGS
cylinder. Make sure the air is off and the breathing system of the mask is unpressurized. To vent the system,
open the bail-out valve on the manifold block on the
diver's harness and push the purge button on the mask.
2) If you have a quick-disconnect fitting on the lowpressure hose between the mask and manifold block,
you can separate the mask here. Otherwise, you will
need to disconnect the low-pressure hose from the
manifold block once the air has been vented.
To disconnect the mask when used in the scuba mode:
1) Turn off the scuba cylinder at the valve.
2) Depress the purge button on the mask until all air is
vented from the first stage regulator, hose, and second
stage in the mask.
3) Disconnect the first stage from the scuba cylinder
and cap the high-pressure inlet filter on the regulator.
WARNING
Never disconnect any hose from the mask
unless all gas has been vented from the
hose first. If the hose is disconnected with
pressure in the line the fittings may be
damaged. In addition, the hose can whip
about causing injury to anyone standing
nearby.
WARNING
Different brands of grease should never be
mixed. Ensure all old grease is removed prior
to applying new grease.
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4.5 Daily Maintenance
The mask should be rinsed thoroughly with fresh clean
water and the post dive procedures followed after each
day of diving. Cleaning is usually performed after the
mask has been disconnected from the air supply.
1) Wash the exterior of the mask with a mild soapy
water solution and rinse thoroughly with fresh water.
Do not depress the purge button while rinsing the
regulator as this action will permit foreign matter back
into the inlet valve and seat.
2) Remove the regulator cover ring, regulator cover,
washer and diaphragm, then clean all components and
swab out the interior of the regulator with the sanitizing
solution as per the sanitizing procedure. Note: avoid
depressing the purge button to minimize water entering the inlet valve.
After cleaning and sanitizing, rinse thoroughly.
3) Screw the demand regulator adjustment knob all the
way out. This will prolong the life of the inlet valve
and keep the internal adjustment correct.
The regulator adjustment knob should be backed all
the way out for storage.
4) Remove the earphones from the earphone pockets.
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.
5) Allow the entire mask to dry in a cool, dry location
prior to storage.
6) Lay the mask face down so that no water will collect in the ear pockets. DO NOT dry the mask or let
it sit in the direct sun light for long periods of time,
as this will degrade the rubber.
7) For additional details on daily maintenance, consult
the Dive Lab website at www.divelab.com
Uncover the earphones so they may dry.
WARNING
Use only mild hand dish washing soap and
water to clean this mask. Do not use any
solvents or petroleum based chemicals.
These may damage the mask frame, leading to failure, flooding of the mask, and
drowning.
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4.6 Inspection Procedures
WARNING
If in doubt about the serviceability of a part,
repair or replace it immediately. Use only
Genuine Kirby Morgan replacement parts.
The use of unauthorized parts may result
in injury or death to the user.
WARNING
Do not use solvents or bleach for cleaning.
These agents are toxic and use of them
may result in injury or death to personnel
and damage to equipment.
WARNING
Wear eye protection to
prevent cleaning and
germicidal cleansing
solutions from contacting eyes. If contact
occurs, rinse eyes with
copious amounts of water and consult
medical help immediately.
WARNING
Cleanliness is imperative in maintaining and
handling Kirby Morgan masks and helmets.
All tools, parts, and components must be kept
free of oil, grease, rust, and other contamination. Foreign substances within an assembly
may result in equipment failure and possible
injury or death to personnel.
Each diver must establish his own minimum standards
for the care of his mask. We offer recommendations
here with the suggestion that the diver establish for
himself what is necessary to provide a good working
unit. Use of the mask in fresh water will require a
timetable for maintenance procedures different from
that when the mask is used in salt water.
Using the mask in sea water while jetting in sand will
necessitate increased maintenance. Use of the mask in
a heavy oil and/or chemical environment may make
it necessary to replace rubber parts to assure proper
function. Regardless, all diving helmets and masks
should be disassembled, cleaned and inspected at least
once a year. All soft goods should be replaced at least
once a year, if needed.
NOTE: Certain fuel oils and/or chemicals will cause
premature degradation of soft goods and seals by making
them become soft, swell or break down. Upon exiting the
contaminant, KMDSI recommends a thorough external
decontamination/washing of the maske as soon as feasibly
possible, followed by a vigilant inspection of the interior
of the mask to ensure that no contaminant has entered.
Pay particular attention to the following parts prior
to re-use; the regulator assembly, demand regulator
diaphragm, demand regulator exhaust valve, and communications connector assembly.
O-Ring Removal/Inspection/Cleaning and
Lubrication
Strict cleanliness and proper lubrication are extremely
important during O-ring installation. Comply with the
following instructions to ensure proper installation:
NOTE: Ensure all parts are clean throughout the
assembly procedure. Dirt or loose particles in the
O-ring groove can cause leaks in the seal and damage to the O-ring, reducing its life. During cleaning
of equipment, carefully clean O-ring grooves, using
a soft bristle brush and mild soap solution.
O-Ring Removal:
Do not use screwdrivers or hard metal picks to remove
o-rings. When possible, only use fingers to remove
o-rings. If an o-ring fits too tightly in its groove to
be removed using the fingers, use the appropriate tool
such as a brass pick (or a wooden toothpick).
A plastic cable tie makes an effective o-Ring removal
tool. Use of an appropriate tool helps prevent scratching the o-ring groove, which can cause leakage or
premature failure of the seal.
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O-Ring Inspection:
If during routine corrective maintenance o-rings are
to be reused, only reuse o-rings that pass a visual inspection. Inspect for deformities or compression set,
hardening or brittleness, nicks or cuts, pits or blisters,
or any other signs of damage. Cut and discard damaged o-rings and replace them with new ones.
O-Ring Reuse:
All o-rings and soft goods should be replaced whenever scheduled overhauls are being completed. During routine repairs or maintenance in between the
overhauls, o-rings and soft goods may be reused after
cleaning provided a careful inspection reveals no wear
or damage.
Place the o-rings in a cleaning basin, cover with mild
soap solution, and brush gently with a soft bristle
brush to remove all traces of old lubricant and contamination.
Rinse cleaned o-rings with fresh water and wipe clean
with lint-free cloths, then allow to air dry, carefully
inspect for cracking, cuts, abrasions and deformities.
Replace o-rings if any damage is found or suspected.
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4.7 General Cleaning Guidelines
Cleaning and sanitizing of the mask should be accomplished upon completion of use and/or prior to
storage. Clean is defined as free of dirt, rust particles,
grease and oil and other contaminants as viewed by
the unaided eye.
Sanitizing is defined as eliminating germs and microorganisms. Sanitizing should be accomplished post
use or prior to use by another user. KMDSI recommends sanitizing be accomplished any time the unit
is to be used by another person during the mission or
operation.
NOTE: The Sanitizing Procedure should be accomplished if possible between dives when two or
more divers are making consecutive dives with the
same mask.
Both the regulator cover and diaphragm should be
removed for cleaning and sanitizing. The inside of
the regulator and whisker must also be sanitized.
Read this manual completely for instructions on how
to remove and replace these components properly.
See the most up-to-date procedures for cleaning on
the Dive Lab website at www.divelab.com.
WARNING
Always sanitize the mask
prior to use by another person. Failure to do could result in the transmission of
communicable diseases,
some of which may cause
long term disability or death.
4.7.1 Mild Soap Solution for General
Cleaning and Leak Detector Use
Maintenance procedures include cleaning with a
general-purpose solution of a mild diluted hand dish
washing soap such as Joy® or Palmolive®. Cleaning
solution is prepared by mixing approximately one teaspoon of soap to 1/2 gallon of warm fresh water. This
solution may also be used as a leak detector solution.
Place all parts and components in a clean washbasin
or sink and immerse in soap solution.
Allow parts/components to soak for at least five minutes, and then scrub using a nylon brush. Carefully
brush all surfaces, paying close attention to O-ring
grooves and threaded surfaces ensuring all greases are
removed. Regardless of the soap used, all components
must be thoroughly rinsed post cleaning to remove all
traces of soap.
4.7.2 Acidic Cleaning Solution and
Procedures
Metal parts that have visible corrosion should first be
cleaned using the soap solution scrubbed with a nylon
bristle brush, then soaked in a solution of 50% white
vinegar and water for less than 60 minutes. They
may also be placed in a ultrasonic sink followed by a
light brushing and thorough rinsing with fresh water
and air-dried. If corrosion is such that 50/50 vinegar
will not clean components, it is best to replace the
components.
4.7.3 Germicidal Cleaning Solutions and
Procedure
Sanitizing of the oral-nasal mask/regulator of Kirby
Morgan masks is accomplished using one of four approved germicidal cleansing solutions. There are four
examples of solutions shown here, along with the necessary ordering information and mixing instructions.
NOTE: Ensure optional face cushion is removed
prior to sanitizing the oral-nasal mask/regulator.
1. SaniZide Plus: P/N: 34805 (spray) or 34810
(gallon), Ready to use; do not dilute.
SAFETEC of America, Inc
1055 E. Delavan Ave.
Buffalo, NY 14215 USA
1-800-456-7077
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2. Advance TBE: P/N: AD160 (spray) or AD1128
(gallon), Infection Control Technology ): Ready to
use.
Infection Control Technology
1751 So. Redwood Rd.
Woodscross, UT 84087 USA
1-800-551-0735
3. Bi-Arrest 2: P/N: BP201 (4 ounces) or BP 222
(32 ounces), Infection Control Technology. Mix two
pumps of the concentrate with 16 ounces of fresh
water.
Infection Control Technology
1751 So. Redwood Rd.
Woodscross, UT 84087 USA
1-800-551-0735
4. Confidence Plus: P/N: 10009971 (32 ounces)
Mix one ounce of concentrate with one gallon of
fresh water.
Mine Safety Appliances 1-800-MSA-2222
Sanitizing Procedure:
Unless otherwise directed, use the following procedure
to disinfect the oral-nasal mask/regulator:
1) Wet or immerse all components to be sanitized.
Allow components to stay in contact with the solution
for at least 10 minutes.
2) If the solution appears to be drying, apply more
solution to keep it wet for the full 10 minutes.
3) After 10 minutes, thoroughly rinse components
under running potable water.
NOTE: The purpose of this procedure is to sanitize the components exposed to each of the divers.
KMDSI recommends sanitizing be accomplished
daily in between use by different divers, after each
use, or when future use is anticipated within the
mission (job) period. KMDSI defines “A mission is
defined as use of the mask over a seven-day period.”
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved.
CAUTION
Germicidal cleansing solutions must be
carefully diluted if required in accordance
with the manufacturer’s recommendation. If solution is not of the recommended
strength, it will not act as an effective
disinfectant. Failure to thoroughly rinse
germicidal cleansing solution from diving
equipment may result in lung irritation
and/or long-term degradation of rubber
and silicone components of this equipment.
WARNING
Do not use solvents or bleach for cleaning.
These agents are toxic and use of them
may result in injury or death to personnel
and damage to equipment.
WARNING
Cleanliness is imperative in maintaining and
handling the Kirby Morgan masks and helmets. All tools, parts, and components must
be kept free of oil, grease, rust, and other
contamination. Foreign substances within
an assembly may result in equipment failure
and possible injury or death to personnel.
WARNING
Use only mild hand dish washing soap and
water to clean this mask. Do not use any
solvents or petroleum based chemicals.
These may damage the mask frame, leading to failure, flooding of the mask, and
drowning.
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4.8 Communications Inspection
Visually inspect the earphones, microphone, wires,
lugs, 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.
4.9 Reassembling the Mask After
Cleaning
Ensure that all the parts and assemblies are completely
dry before assembling or storing.
1) Install the oral nasal and equalizer if they were
removed.
2) If so equipped, install the communications in accordance with this manual. If no communications are
used, the hole in the microphone cup in the oral nasal
must be plugged. Use KMDSI oral nasal microphone
plug, part # 320-001.
3) When storing the mask, make sure the regulator
adjustment knob is backed all the way out. This will
prevent wear to the regulator seat and lengthen its useful
life. Store the mask with the earphone pockets facing
straight back or inward. This will help the rubber keep
its shape better than stored with the earphone pockets
facing outward.
All the O-rings should be replaced at least once a year.
The inlet valve on the EXO Standard and Original
should also be replaced once a year. The EXO BR inlet
valve will not require annual replacement as long as
it is routinely cleaned and lubricated and there is no
evidence of corrosion or damage.
Regularly inspect and test the communications components.
All the EXO masks were designed for minimal maintenance. It is important to carefully inspect the mask after
post dive maintenance to ensure it has been properly
cleaned and dried prior to storage.
Your entire regulator should be rebuilt every year. To
perform an entire regulator rebuild (including the
exhaust valve) or to replace the face seal, the regulator
mounting tools must be purchased.
WARNING
All parts on Kirby Morgan masks and
helmets must be adjusted to their proper
torque specifications. See Appendix 1 for
a complete listing of torque specifications
for each part. Failure to adjust parts to
the recommended specifications could
lead to helmet failure and accidents. This
could be fatal.
WARNING
Different brands of grease should never be
mixed. Ensure all old grease is removed prior
to applying new grease.
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Chapter 5
EXO Regulator Maintenance
5.1 General Information
the regulator is a difficult procedure, and will require
the KMDSI regulator mount nut tool. Complete mask
disassembly is possible provide the user has the proper
KMDSI tools. However, it is recommended that this
service be performed by a factory trained KMDSI
Dealer. Contact KMDSI at (805) 928-7772 for your
nearest factory trained service center.
When regulator parts need changing, cleaning, or the
regulator has gone out of adjustment, read all of the
following and refer to the diagrams and blowaparts
to become familiar with all parts and terms associated with the areas of the mask prior to any disassembly of the regulator. There are two types of EXO
regulator covered in this manual, the EXO original/
standard and the EXO-BR (balanced regulator), with
disassembly and rebuild sections for each.
Note: If you are doing a regulator rebuild and are
changing the exhaust valve, it is possible to do a
replacement without completely removing the regulator. Follow the directions for disassembly of the
regulator. Then follow the directions for removing the
regulator, but instead of taking the regulator mount nut
completely off, only loosen it enough for the regulator
to be pulled slightly forward, then pull the whisker
off of the regulator body to access the exhaust valve.
All EXO demand regulators are initially adjusted and
preset at the KMDSI. factory using an intermediate
pressure of 135-150 p.s.i. The EXO regulator is an adjustable second stage regulator. This allows the masks
to work well over a wide range of pressures and diving
conditions.
The EXO Standard and Original masks should be
overhauled every year. This includes O-ring and inlet
valve replacement. The EXO-BR demand regulator
should be dissembled, cleaned, and inspected every
six months.
The inlet valve on the EXO-BR normally sees very
little wear, so replacement is only needed after every
twenty-four months. Because the EXO-BR inlet valve
is of a pneumatically balanced design, the EXO-BR
demand regulator inlet valve requires more frequent
cleaning and lubrication than the EXO Standard and
Original. The inlet valve should be removed and both
the inlet valve and the main tube should be cleaned
and inspected every six months.
After cleaning and inspecting the inlet valve, the balance O-ring should be lubricated. This procedure can
be complete with out removing the demand regulator
assembly. Normal overhaul does require replacement
of all regulator O-rings.
Replace the exhaust valve making sure that it is facing
the right direction and seated correctly. Then put the
exhaust whisker back on and follow the directions for
installing the regulator. Following this procedure saves
you from having to remount the regulator in the mask
seal and frame and from possible cross threading of
the regulator body while putting the regulator mount
nut back on.
5.1.1 Special Regulator Tools
There are two special tools that will assist you in
maintaining your EXO regulator. They are as follows:
KMDSI Part #325-620 Spanner wrench
KMDSI Part #325-625 Back-up wrench
Normal annual overhauls of the EXO demand regulators
DO NOT require you to completely remove the regulator can body from the mask. Removing and reinstalling
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EXO Full-Face Mask Manual
CAUTION
Use only Kirby Morgan original replacement parts when repairing your mask.
The use of other manufacturer’s parts
will interfere with the performance characteristics of your equipment and may
jeopardize your safety. Additionally, any
substitutions will void any warranties
offered by KMDSI. All of the spare parts
listed on the blowapart drawings were
specifically manufactured by KMDSI for
use on the EXO. When ordering spares,
always insist on KMDSI original parts.
The EXO Original and Standard regulator
5.2 Original and Standard EXO
Regulator Disassembly
Tools required:
13/16" open end wrench, 5/8" open end wrench
IMPORTANT NOTE: This section is for the EXO
original and standard regulators which are no longer
produced. If you have the EXO BR, follow the procedures for that system covered later in this chapter.
1) Unscrew the regulator cover assembly and remove
40
Always use a back up wrench on the main tube when
loosening the packing nut to prevent possible damage
to the regulator.
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EXO Full-Face Mask Manual
knob assembly from the regulator.
3) Position the mask so that the adjustment knob end
is pointed down and shake out the spring and spacer.
4) Push the adjustment side of the main tube about 3/8"
into the regulator body. This will be enough to allow
the roller lever to be removed from its slot.
Remove the roller lever.
5) Once again position the adjustment knob end of
the main tube downward and gently shake the mask to
The adjustment assembly is removed after the packing
nut is loosened.
Push the main tube out enough to allow the lever arm
to be removed.
Remove the spring and spacers.
the washer and diaphragm.
2) Back out the adjustment knob far enough to allow
a 13/16" open end wrench to fit onto the packing nut.
Place a 5/8" open end wrench, or the wrench provided
with the mask, on the opposite side of the main tube.
This will be used as a back up wrench to keep the main
tube from spinning when loosening the packing nut.
Loosen the packing nut and unscrew the adjustment
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved.
Remove the roller lever arm.
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EXO Full-Face Mask Manual
Inspect the nipple tube seating surface for dings, nicks,
and wear. You should be able to feel any irregularities
with your fingernail.
Gently shake out the inlet valve.
dislodge the inlet valve. Remove the inlet valve.
6) Keep pushing the main tube through the regulator
body until the horseshoe is centered in the regulator
body. Remove the horseshoe from the main tube by
sliding it off.
7) Remove the main tube by continuing to push it
through the regulator body
8) Loosen the adjustment lock nut on the nipple tube
and unscrew the nipple tube from the main tube.
Inspect the nipple tube seating surface for dings, nicks,
and wear. You should be able to feel any irregularities
with your fingernail. If the tube is damaged it must
be replaced.
9) Inspect and clean all parts. All the O-rings should
be replaced at least once a year. Lubricate all O-rings
lightly with silicone grease. Inspect the seat on the
inlet valve. There should be no cuts or nicks in the seat.
Replace inlet valve if seat is damaged.
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5.3 Original and Standard EXO
Rebuild
After all parts have been cleaned, inspected, and lubricated lightly with silicone grease as needed, make
sure all O-rings are in their appropriate places.
1) Install the nipple tube into the main tube. Make
sure the adjustment locknut is on the nipple tube before
screwing it in. Screw the nipple tube all the way in then
back it out about 1/8". Snug the lock nut up against the
main tube.
2) Slide the main tube into the regulator body. The
main tube should be oriented so that the air inlet hole
(the big one in the middle) will be facing up towards the
diaphragm. This position will make the horseshoe easier
to install. Keep sliding the tube in until the horseshoe
area of the main tube is centered in the regulator body.
3) Slide the horseshoe into its place on the main tube
from inside the mask. Now rotate the main tube to
orient the air inlet hole to face towards the inside of
the mask (180 degrees).
4) Keep pushing the main tube in until it is about 3/4
of the way in.
5) Reinstall the inlet valve, rubber seat first, into the
adjustment knob end of the main tube. Tilt the mask and
gently shake it until the skinny part of the inlet valve
is aligned with the roller lever slot in the main tube.
6) Install the roller lever and push the main tube the
rest of the way through. Make sure that the roller lever
is caught in the skinny area of the inlet valve. Make
sure that the exhaust whisker is properly seated on the
main tube
7) Reinstall the spring and spacer, spring first, into
the main tube.
8) Reinstall the adjustment knob assembly and tighten
the packing nut. Remember to use a back up wrench
on the other end of the main tube when tightening the
packing nut to prevent the main tube from spinning.
Tighten packing nut to 40 inch pounds of torque.
Make sure the exhaust whisker is properly seated on
the main tube.
nut down against the main tube and put the diaphragm
and washer with cover back on.
10) Replace the diaphragm washer and screw in the
regulator cover assembly and follow the Regulator
Adjustment procedures in this chapter.
CAUTION
Pre-1998 EXO masks used an aluminum
inlet valve. If you are overhauling a mask
and find one of these aluminum valves we
recommend replacing it with a new plastic
inlet valve.
Note: If the knob is out too far when tightening the
packing nut, the nut will not seal or tighten completely.
9) Make sure the lock nut is threaded all the way on
the nipple tube. Screw the nipple tube in until you see
the roller lever arm just move, and then stop. Lock the
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EXO Full-Face Mask Manual
5.4 EXO Balanced Regulator
Disassembly
Tools required:
11/16" open end wrench
5/8" KMDSI back up wrench.
All plastic or brass handled tube brush
Nylon tooth brush
The inlet valve of the EXO-BR requires frequent cleaning and lubrication due to the exacting tolerances of
the inlet valve mechanism. Once familiar with this
procedure the task can be accomplished in about 1015 minutes.
A few words of CAUTION! Use only mild soap such
as hand dish washing soap. Use only a tube brush that
is all plastic, or does not have an exposed metal tip.. A
tube brush with hard metal components could scratch
the chrome surface of the balance chamber. If O-rings
are to be removed, use only a plastic pick or toothpick.
Use of a metal pick could scratch delicate surfaces.
Remove the regulator cover.
1. With mask disconnected from a pressure source,
remove the hose from the nipple tube. If the nipple
tube is equipped with the swivel remove the swivel
from the nipple tube.
2. Unscrew and remove the regulator diaphragm cover,
then remove the thrust washer and diaphragm.
3. Back out the regulator adjustment knob far enough
to allow the 11/16" open end wrench to fit on to the
packing nut. Place the 5/8" KMDSI wrench on the hex
on the opposite end of the main tube, then loosen the
packing nut and remove the regulator adjustment knob.
Shake the mask, and allow the spring and two spring
spacers to drop free.
Remove the diaphragm and washer.
Always use a back-up wrench for removal of the adjustment knob assembly.
Unscrew the adjustment knob assembly from the
regulator.
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Remove the spring and spacers.
Carefully push the inlet tube into the regulator body.
4. Using the thin 5/8 KMDSI wrench on the main tube
body and a standard 5/8" wrench on the nipple tube jam
nut, loosen the jam nut. Carefully unscrew and remove
the nipple tube from the main tube. Be careful not to
drop or bump it as the seating surface is very delicate
and can be easily damaged. Set it aside where it will
not be damaged.
5. Carefully push the adjustment knob side of the
inlet tube into the regulator body approximately 1/4"
to 3/8". This will allow the lever arm to be removed.
After removal, push the main tube the same direction
to locate the horseshoe clip at the center of the regulator. Rotate the main tube 180 degrees and remove the
horseshoe clip.
6. Shake out the inlet valve, it will drop through the
inlet nipple side of the tube. At this point the cleaning
and maintenance can be performed without further
disassembly, However, should you desire, the tube can
be taken out completely.
Remove the roller lever arm.
7. Mix a solution of mild hand dish washing soap and
warm water. Using the tube brush, carefully clean
the balance chamber located approximately 1 1/2" in
from the center of the main tube in the direction of the
regulator adjustment knob end. The balance chamber
is machined to exacting tolerances and only requires
a gentle brushing. USE EXTREME CAUTION
WHEN CLEANING THE BALANCE CHAMBER. A brush with hard metal components could
damage the balance chamber.
8. If the main tube was removed, clean the tube using the toothbrush. Gently clean the exterior surface,
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved.
Document #130418001
Removing the nipple tube.
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EXO Full-Face Mask Manual
for wear and damage replace if necessary.
11. Clean the inlet nipple tube using the toothbrush and
soapy water. Gently work the bristles in and around the
O-ring surfaces. Rinse thoroughly with fresh water and
blow dry. Carefully inspect the O-rings for damage,
replace if necessary. Carefully inspect the knife-edge
of the nipple tube for nicks and dings.
The knife-edge of the nipple tube must be free of any
damage. You should be able to feel any irregularities
with your fingernail. If the tube is damaged it must
be replaced.
Handle the inlet valve with care.
working the bristles in and around the O-ring grooves
of the two static O-rings. Thoroughly rinse with fresh
water and blow dry with compressed air. Inspect the
exterior of the two O-rings for damage. Replace if any
damage is found.
After all parts have been cleaned and inspected. Lightly
lubricate all O-rings and O-ring surfaces with silicone
grease. Work the grease into the O-ring grooves then
rotate the O-rings to spread the lubricant and wipe off
any excess.
9. Using the toothbrush and soapy water, carefully
scrub the inlet valve to remove all dirt, salts, and old
lubricant. Normally, it is not necessary to remove the
inlet valve O-ring in between annual overhauls, as long
as the O-ring groove is not heavily corroded. If heavy
corrosion is present, the O-ring should be removed
using a plastic O-ring pick.
Using the nylon toothbrush, carefully clean the inlet
valve by working the bristles carefully in and around
the O-ring and O-ring groove. Rinse thoroughly with
fresh water and blow dry with compressed air. Carefully inspect the O-ring groove by gently rocking the
O-ring from side to side.
Inspect the nipple tube seating surface for dings, nicks,
and wear. You should be able to feel any irregularities
with your fingernail.
The O-ring groove should be free of pitting and corrosion damage. Carefully inspect the soft seat surface
for cuts, nicks and abrasions. Normally, the soft seating
area will have a slight round depression where it lays
against the metal seat. This is normal.
Blow lightly through the 1/8" balance tube shaft with
your lips to ensure air passes freely through the inlet
valve. Replace the inlet valve if no flow is detected, or
if any corrosion or soft seat damage is apparent.
10. Clean the regulator adjustment knob shaft and
O-ring using the soapy water and toothbrush. Rinse
thoroughly and blow dry. Carefully inspect the O-ring
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Exhaust
Whisker
Packing
Nut
Regulator
Body
Spring
Set
Spacer
Knob
Sleeve
Pin
Horseshoe
Adjustment
Shaft
Exhaust
Valve
Inlet Valve
Washer
Spring
Nut
Roller
Lever
Main
Tube
Nipple Tube
High-Flow Swivel
Blowapart drawing of EXO-BR
regulator assembly
Diaphragm
Cover
Purge
Button
5.5 EXO-BR Regulator Reassembly
1) After all parts have been cleaned, inspected, and
lubricated lightly with silicone grease as needed, make
sure all O-rings are in their appropriate places.
2) If the main tube was completely removed from the
regulator body, reinstall it by sliding it into the regulator
body. The "B" that is machined into the main tube at
the nipple end should be facing "up," i.e., towards the
diaphragm, or exterior front of the mask.
Keep sliding the tube in until the horseshoe area of the
main tube is centered in the regulator body. If the main
tube was not removed it will already be positioned for
acceptance of the horseshoe retainer.
Tip: When in this position, rotate the main tube 180
degrees to allow easier installation of the horseshoe
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved.
The B on the nipple tube should be facing "up," i.e.,
towards the diaphragm, or exterior front of the mask.
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The horseshoe is critical to the proper function of the
regulator.
Be sure to lubricate the inlet valve sparingly with
silicone grease.
The horseshoe as seen from the interior of the regulator where it is installed on the main tube.
Installation of the spring set.
clip. Then rotate the main tube 180 degrees or follow
step 3.
5) Slide the roller lever into the roller lever slot on the
main tube. Make sure that the inlet valve is caught
by the roller lever and push the main tube all the way
into the regulator body. Make sure that the exhaust
whisker is seated in the groove around the main tube
at the nipple tube end.
3) Slide the horseshoe into place on the main tube
from inside the mask.
4) Slide the inlet valve into the main tube from the
nipple tube side, sliding it in until the inlet valve is
seated into the tube.
48
6) Place the spacer, spring, and spacer together and
slide this assembly into the main tube from the adjustment knob end. Make sure that the spacers go in
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straight and move freely. (Tip: It is easier to
position the main tube straight up and insert the spring
and spacers up into the tube.)
7) Reinstall the adjustment knob assembly and tighten
the packing nut. Always use a back up wrench on the
other end of the main tube when tightening the packing nut to help prevent the main tube from damaging
the regulator body. Tighten the packing nut to 40 inch
pounds.
The lever arm should now have some spring tension
and the spring into an up position when depressed
and released.
8) Install the nipple tube into the main tube. Make sure
the adjustment lock nut is all the way on the nipple
tube before screwing it in. Screw the nipple tube in
until the lever arm moves just slightly.
Install the regulator cover.
Note: If the knob is out too far when tightening the
packing nut, the nut will not seal or tighten completely.
9) Make sure the lock nut is threaded all the way on
the nipple tube. Screw the nipple tube in until you see
the roller lever arm just move, and then stop. Lock the
nut down against the main tube and put the diaphragm
and washer with cover back on.
10) Install the diaphragm, washer and regulator cover
assembly. Follow the Regulator Adjustment procedures in this chapter.
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EXO Full-Face Mask Manual
5.6 Regulator Assembly Removal and
Installation
Tools required:
3/8" ratchet with an extension.
EXO Tool Kit, Deluxe. KMDSI Part #325-650.
This can be a difficult procedure. It is recommended
that this procedure be done by a factory trained KMDSI
dealer. If you are going to attempt this procedure read
and understand this entire section before you start
disassembly!
If you are doing a regulator rebuild, the regulator
must be removed from the from the mask in order to
replace the exhaust valve.
5.6.1 Regulator Assembly Removal
1) Remove the spider and the communications module.
See Chapter 6 and 7.
2) Remove the inlet tube of the EXO original (or cut the
tie wrap if you have an old style oral/nasal) and remove
the EXO Standard or BR oral nasal and equalizer.
3) On the EXO Standard or BR, remove the screws
and washers that hold the wire retainer on and remove
the wire retainer.
4) Using the regulator mount nut tool on a 3/8" ratchet
with an extension is the easiest method of removing
the regulator mount nut.
5) With the mask face down in your lap, place the
regulator mount nut tool in the grooves of the regulator
mount nut. Remove the regulator mount nut.
6) Remove the mount ring.
7) Gently pull straight out on the regulator assembly,
removing it from the mask.
Inlet Tube
Mask Seal
Mount Nut
Regulator
Mount Washer
Mask Frame - EXOskeleton
Regulator Assembly
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Oral/Nasal
Mask
Wire Retainer
Mount Nut
Regulator Mount
Washer
Frame,
EXOskeleton
Tie Wrap
Equalizing
Device
Mounting Ring
Blowapart drawing of the regulator assembly
installation on EXO Standard and BR.
Mask Seal
Regulator
Assembly
8) Remove the regulator mount washer from the inside
of the mask.
To remove the regulator, you must remove the regulator mount nut.
A pliers can also be used to grip and turn the regulator removal tool.
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EXO Full-Face Mask Manual
5.6.2 Regulator Assembly Installation
1) Inspect the mask seal in the regulator area for tears
or holes and replace if damaged. Ensure that the mask
seal is properly mounted into the frame. This is what
seals the regulator to the mask. It is very important
that the seal in this area remain correctly seated in
the frame and does not get pushed through during all
phases of installation.
2) Once the seal is correctly in place, lightly lubricate
the inside of the regulator mounting hole in the mask
seal with silicone grease. Do not get grease between
the mask seal and the frame. If the grease gets between
the frame and the mask seal, the mask seal will become unmounted and push through more easily when
installing the regulator. Lightly grease the threads on
the regulator body.
Good
3) Holding the mask in one hand and the regulator assembly in the other with the exhaust whisker openings
pointed down to the bottom of the mask, insert the
regulator assembly into the mask. Hold the regulator
at a slight angle when you first start to push it through
the opening then straighten it out as you go in.
Start the threads of the regulator partially in on one
side of the opening then work it into the hole. On the
inside of the mask use your finger tips to support the
mask seal to keep it from being pushed to the inside
of the frame.
Once the regulator is in, visually inspect the mask seal
on the inside of the mask and make sure that the mask
seal did not get pushed through and that it is still
correctly seated on the frame. If the seal has been
pushed through, take the regulator out and try again.
Once the regulator is properly seated, inspect where
the exhaust whisker meets the frame and make sure
that the whisker is properly seated into the groove of
the front of the regulator mount area on the frame.
4) Lightly lubricate the regulator mount washer and
install it on the regulator.
5) Place the mount ring inside of the mount nut. The
pressed in insert on the mount ring should have the
bumps facing the regulator.
Bad
Make sure that the mask seal did not get pushed
through past the regulator body.
you feel the nut drop onto the threads (you may hear
a slight "click" when this occurs). Then, gently thread
on by hand as far as possible to ensure that it does not
cross thread.
Cross threading can damage the regulator body. If
the threads are damaged in any way the can must be
replaced. Once the mount nut is on correctly, start
tightening. Once again, check and make sure that the
exhaust whisker is properly seated in the frame before
final tightening. Tighten the regulator mount nut to 100
inch pounds.
7) Put the mount ring adjustment tool on the ratchet
The mount nut must not
be cross threaded!
6) Thread the Mount Nut onto the regulator assembly.
The mount nut must go on straight. Do not cross thread!
It is easiest to start the mount nut by hand. Put the nut
on the regulator, slowly turn counterclockwise until
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equalizing device onto it’s mount.
The mount ring adjustment tool is essential for
correct mounting of the
regulator.
12) Reinstall the communications in accordance with
Chapter 6.
extension and mount the tool into the mount ring.
Turn the mount ring until it is horizontally aligned (see
photo this page).
8) On a EXO Standard or BR, reinstall the wire retainer
with the screws and washers.
9) Reinstall the inlet tube (EXO Original) or:
10) Reinstall the oral nasal mask( EXO BR) and properly
align the nose cavity. Make certain the round mount
lip is properly / completely inserted into the mating
groove found on the regulator oral nasal mount nut.
11) If you are using the new style silicone oral/nasal a
tie wrap is not required for installation. However, if
you are using the old style oral/nasal, install the new
tie wrap. Insert the tail of the tie wrap into the head
and pull it through about 1.5” This will allow enough
circle to fit over everything during installation. Begin
installation by carefully folding the oral nasal mask
in on itself only enough to allow the tie wrap to pass
over the outside of it.
Be careful not to displace the oral nasal from the groove
of the regulator mounting ring. Double check making
sure the oral nasal is seated in the groove. Carefully
begin tightening the tie wrap, while pushing it down
against the regulator mount nut. Direct the head of the
tie wrap towards the channel inside the main mask
cavity, found at about the 9:00 O’clock position.
Before the tie wrap is closed tight, check again to be
sure the oral nasal is still in the groove. Hold the tie
wrap down against the mount nut and tighten with
needle nose pliers. Snip off any excess tie wrap material as close to the head as possible.
Check the installation by lightly tugging at the oral
nasal. It should remain seated. If it pulls free, repeat
steps 4 thru 9 with a new tie wrap.
If the installation tests properly, reinstall the microphone
into the pocket in the oral nasal. Re install the nose
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5.7 EXO Regulator Adjustment
NOTE: After working on the regulator it must be
checked for proper adjustment and function. You do
not need to let the EXO regulator sit for 24 hours. Make
certain the inlet nipple and inlet valve were pre-set
properly before final adjustment.
1) Ensure the diaphragm cover and diaphragm are
removed and the inlet nipple and lock nut are loose,
then back the inlet nipple out counter clockwise about
four to five turns.
2) Adjust the adjustment knob in fully clockwise then
back it out 3 full turns.
3) Rotate the inlet nipple in slowly until the lever starts
to drop then stop. Snug the locknut by hand to keep
the inlet nipple from moving.
4) Attach an air source at a supply pressure of between
135 and 150 p.s.i.g.
5) Slowly pressurize the regulator then back out on the
adjustment knob until a slight free flow develops then
rotate back in until the free flow just stops.
Use the spanner wrench to depress the purge button
while turning the nipple to adjust the regulator.­
7) Install the diaphragm, thrust washer, and secure
the cover.
8) Lightly depress the purge button. A slight flow of
gas should be heard when the purge button is depressed
1/16-1/8”, and a strong purge should be present when
the button if fully depressed.
9) Once the regulator is installed and adjusted the retainer wire for the equalizer device is installed. Tighten
the screws to 10 inch pounds.
10) Install the nose block/equalizing device rubber pad
at the correct height for your face.
Use a supply pressure of 135-150 p.s.i. to adjust the
regulator.
At this point adjust the lever so that it has between 1/16th
to 1/8”of free play at the end of the lever. To increase
the play in the lever, turn the inlet nipple 1/8 of a turn
at a time. To decrease the lever play, rotate the inlet
nipple counter clockwise 1/8 of a turn or less at a time.
6) Once the end play of between 1/16th to 1/8’’ has
been achieved, tighten the lock nut against the main
tube using the two flat wrenches in the tool kit.
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After the regulator is adjusted, install the wire retainer
for the equalizing device.
Install the nose block rubber pad at the appropriate
height for your face.
Tighten the screws for the nose block wire retainer.
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EXO Full-Face Mask Manual
5.8 Manifold Block Maintenance
5.8.1 Daily Maintenance
A daily pre-dive inspection should be done prior to
using the Manifold Block. Carefully inspect the assembly for any sign of damage or worn components.
Tools: open end wrenches, 1", 11/16", 9/16", 5/8" and a
5/16 Allen wrench.
1) Check to ensure all the port plugs are installed and
are tight.
2) Check to ensure the auxiliary gas supply whip is
installed and tight, on the auxiliary valve
3) Using a 5/8" open-end wrench, check to ensure the
packing nut on the auxiliary valve is snug. Note: do
not over-tighten. The valve handle should turn freely.
Check to ensure the packing nut does not turn -when
a light force is applied with the wrench.
4) Ensure the non-return valve and umbilical adapter
are securely in place.
KMDSI Manifold
Block
5.8.3.1 Disassembly Of Manifold Block
1) Remove the two flat head screws from the manifold
backing plate, and remove the plate.
2) Remove all hoses and port plugs. Remove the O-ring
from each plug and place the plugs in a solution of
50/50 white vinegar and water.
5) Test the one way valve by sucking on the inlet fitting
with your lips. If any air is drawn through the valves
the valve must be rebuilt or replaced.
3) Using a soft jaw vise or a rag wrapped around the
manifold block to keep from marring the finish, remove
the one way valve from the manifold block using the
1" wrench.
5.8.2 Post Dive Procedures
Daily post dive maintenance of the manifold block
requires a brushing with a solution of mild soapy water
and a thorough rinsing with fresh water. If hoses have
been removed, ensure port plugs have been installed and
the umbilical connection has been capped or bagged.
NOTE: The one way valve must be removed from the
manifold block before the auxiliary valve.
5.8.3 Annual Overhaul of the Manifold Block
Assembly
The KMDSI manifold block should be rebuilt on an
annual basis, or when damage or corrosion is suspected
or found.
Tools required: Table vise, 1 "open end wrench (2ea), l
l/16", 5/8", and 9/16" open end wrenches, large flat blade
screwdriver, 5/16 Allen wrench, 0-300 in lbs. torque
wrench, Soft nylon tooth brush, brass O-ring pick and
a solution of 50/50 white vinegar and water.
Parts required:
Manifold Repair Kit KMDSI PN 325-095
56
4) Using the 9/16 open-end wrench, loosen and remove
the auxiliary valve from the manifold block.
5) Place the manifold block body in a solution of vinegar
and water, and allow to soak while the other components
are being disassembled. Using the I " wrench and the
9/16 wrench, loosen and remove the umbilical adapter
fitting. Place it in the vinegar solution.
6) Carefully clean the manifold block body with a nylon
toothbrush and vinegar solution. Remove all traces of
old lubricants, dirt and corrosion, rinse with fresh water
and blow dry with compressed air or allow to air dry.
Using the nylon brush, clean the manifold plate and
umbilical adapter. Take special care to remove all
the old Teflon tape from the threads of the umbilical
adapter. Air or blow dry. Inspect all threaded ports for
any damage.
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5.8.3.2 Disassembly and Cleaning of the
One Way Valve.
Tools Required:
Soft Jaw Vice
1 inch Open End Wrench Attachment
on Torque Wrench
(If no vise is available use a backup 1 inch open end
wrench)
To disassemble and inspect the one way valve assembly:
1) Use two wrenches or hold the hex part of the body in
a soft jaw vise while removing the seat with a wrench.
As the seat is removed, the wiper and the O-ring slide
CAUTION
Do not use pliers on the main body of the
one way valve. You may damage the valve
if pliers are used.
out in place in a groove on the seat. The poppet and
the poppet O-ring usually come out in the seat being
followed by the spring. The only functional part remaining in the valve body is a non-moving, pressed-in
cage. The function of the cage is to prevent the poppet
O-ring from blowing out of place during high flows.
2) Inspect the body interior for foreign matter of any
type and clean, if necessary.
3) Inspect the seat, wiper, O-ring, poppet O-ring and
poppet for wear, replace if necessary. Be sure each
part is clean. A repair kit is available for replacement
parts. (KMDSI Part #525-330)
4) Place silicone lubricant on the components, then
wipe clean with a non-lint producing cloth. Be careful to wipe the poppet and poppet O-ring thoroughly,
removing nearly all silicone to prevent foreign materials
from sticking to these components.
5) Inspect the spring and clean or replace if necessary.
5.8.3.3 Reassembly of the One Way Valve
1) Slide the new O-ring over the poppet.
2) Insert the new spring into the valve body, followed
by the poppet.
3) Next, install the new O-ring and new wiper on the
seat. Thread the seat into the valve body .
4) Tighten the seat to 150 inch pounds with a torque
wrench while holding the body in a soft jaw vice or
Never use pliers on the one-way valve!
Adapter
Wiper
O-ring
Seat
O-ring
O-ring
Poppet
The correct assembly order for the one way valve
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved.
Spring
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EXO Full-Face Mask Manual
with another wrench.
5) Re-tape the pipe threads on the umbilical adapter
fitting with Teflon tape, starting two threads back. One
and one half wraps is all that is required. Reinstall the
umbilical adapter and securely tighten.
NOTE: The one way valve must be installed in the
manifold block after the auxiliary valve.
6) Lightly lubricate a new O-ring, and install onto the
one way valve body. Reinstall the one way valve into
the manifold block only after the auxiliary valve has
been installed. Torque to 150 inch pounds.
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5.8.3.4 Disassembly of the Emergency Gas
Supply Valve
Tools Required:
11/16 inch Open End Attachment on Torque Wrench
1 inch Open End Attachment on Torque Wrench
3/8 inch Slotted Flat Blade Screwdriver
8 inch Adjustable Wrench
2) Inspect the packing and washer for wear and replace
if necessary.
1) To remove the auxiliary valve body from the manifold
block the one way valve assembly must first be removed.
4) Check the seat in the auxiliary valve body for wear
or unevenness. Replace the body if necessary.
NOTE: If only the auxiliary valve is being serviced, it
does not have to be removed from the manifold block
to be rebuilt.
5.8.3.6 Reassembly of Emergency Gas
Supply Valve
Tools Required:
11/16 inch Open End &1 inch Open End Attachments
on Torque Wrench
3/8 inch Slotted Flat Blade Screwdriver
Soft jaw vice, Teflon tape
2) Remove the lock nut, spring, and knob.
3) Undo the packing nut. When the packing nut is free
of the threads of the auxiliary valve body (8), back out
the stem until it is free of the auxiliary valve body.
4) Remove the packing nut, packing, and washer from
the stem.
5.8.3.5 Cleaning and Lubricating the
Emergency Gas Supply Valve
1) Clean all the metal parts in a 50/50 dilute solution
of white vinegar/water. Rinse with fresh water.
Components of the Emergency Gas Supply Valve
3) Inspect the stem seat for unevenness or wear and
replace if necessary. It must also be replaced if the
stem is bent.
1) With the exception of the tapered pipe thread end
of the auxiliary valve body, lubricate all components
with a light coating of silicone grease.
2) Place the new Teflon washer and new packing on the
stem. NOTE: There are two different packings and
washers supplied in the kit, for rebuilding both the
older style and the newer high flow auxiliary valve.
Match the removed packing and washer to the new
ones supplied and discard the others.
Valve Body
Packing
Knob
Lock nut
Valve Stem
Washer
Packing nut
Spring
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EXO Full-Face Mask Manual
supply source. There must be no leakage of gas past
the stem or through the packing nut. Turn on the bailout bottle and leave the supply on for several hours.
There must be no drop in pressure in the system if the
valve is operating properly.
11) Apply Teflon tape to the pipe threads starting two
threads back. Only one and one half wraps is all that
is necessary.
Inspect the packing and washer
3) Holding these components in place on the stem,
screw the stem into the auxiliary valve body.
12) Reinstall the auxiliary valve into the manifold
block and tighten. Ensure the valve body is oriented
in the proper position so that the one way valve can
be reinstalled.
4) Rotate the stem until it is seated all the way in.
5) Thread the packing nut onto the body. Run the nut
in and tighten slightly with a wrench.
6) Place the knob onto the stem and rotate the stem
all the way out, then back again. The rotation must be
smooth. If “hard spots” or unevenness are felt during
the rotation, the stem may be bent and could need
replacement.
7) Tighten the packing nut with a wrench until moderate resistance is felt when turning the knob.
8) Place the spring and locknut onto the stem, securing the knob.
9) Tighten the locknut until the screwdriver makes
contact with the stem. The assembly is now complete
and ready for testing.
10) Test the valve by attaching it to an auxiliary air
WARNING
Take care not to allow any pieces of Teflon
tape to enter the manifold block. If these
pieces of tape enter the demand regulator assembly they may block the flow of
air to the diver. This could lead to death
from suffocation.
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5.9 Overpressure Relief Valve (P/N
200-017) Overhaul Procedures
Over Pressure Relief Valve Component breakdown
Nylon toothbrush
Vinegar, Fresh water
Mild dish soap
Ultrasonic sink, if available
Magnifying glass
New valve body o-ring
5.9.2 Overpressure Relief Valve Disassembly
and Cleaning
WARNING
Overpressure
Relief Valve
Do not use cleaning solvents (i.e. mineral spirits, bleach, etc.) when cleaning
the overpressure relief valve. The use
of cleaning solvents may lead to failure
of the overpressure relief valve.
Seat
Spring
Adjustment
Screw
O-ring
5.9.1 Overpressure Relief Valve General
The overpressure relief valve should always be used on
all Emergency Gas Supply (EGS/bail-out) first stage
regulators to prevent the hose from rupturing in the
event the first stage pressure creeps. The Kirby Morgan
relief body is made of stainless steel.
The basic components last a long time but the valve
should be disassembled, cleaned, and inspected at
least once a year or whenever it fails testing. The valve
should be tested monthly. Cleaning and overhaul is
easily performed using a nylon toothbrush and a 50/50
solution of vinegar and fresh water. Cleaning for 15
minutes in an ultrasonic sink, if available, with the
50/50 vinegar solution is highly recommended.
Repair parts are available. Order P/N 225-017 Overpressure Relief Valve Rebuild Kit, which contains the
O-ring, soft seat, spring, and adjustment screw. The
O-ring should be replaced at least annually. The other
parts require replacement only if worn or damaged. An
exploded view of the valve is located in all KMDSI
Helmet and Band Mask Operations and Maintenance
Manuals. The descriptions used on the next two pages
refer to the drawing on this page.
Tools Required.
Torque wrench
1/2” open-end wrench attachment for torque wrench
1/8” Allen wrench
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved.
1) Turn off the gas supply to the first stage regulator,
then bleed off any remaining pressure. Remove the
first stage regulator from the air/breathing gas source
so it cannot be accidentally turned on, i.e., pressurized.
Make sure the intermediate pressure in the regulator
hose is also fully drained of pressure.
2) Remove the overpressure relief valve from the regulator body using the 1/2” open-end wrench.
3) Remove, cut, and discard the overpressure relief
valve body O-ring.
4) Using the 1/2” open-end wrench to hold the overpressure relief valve body, use the 1/8” Allen wrench to
remove the Allen head adjustment screw. Then, shake
out the spring and soft seat.
5) Place all parts in the 50/50 solution of vinegar and
water and allow to soak for 15 to 30 minutes. If using
an ultrasonic sink, reduce time to 15 minutes.
6) Using the nylon toothbrush, brush all components
to remove corrosion and mineral deposits. Then, rinse
with fresh water and blow or air dry.
7) Using the magnifying glass, carefully inspect all
components for excessive corrosion and/or damage.
Replace the spring and/or adjustment screw, if either
part is excessively corroded or shows signs of wear
and/or damage.
Inspect the soft seat for nicks, cuts, and wear and
replace if any damage is found. Replace the entire
assembly if any damage to the valve body is present.
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NOTE: A deep groove in the soft seat is normal.
Replacement is only necessary if the rubber seat is
deteriorated, cut, and/or chipped.
5.9.3 Overpressure Relief Valve Reassembly
1) After cleaning, inspection and/or parts replacement,
reassemble the valve by installing the soft seat, spring,
and adjustment screw. Tighten the adjustment screw
down until it is approximately 1/2 thread from being
flush with the top of the valve body.
2) Lightly lubricate a new body O-ring, then install on
the valve body.
3) Test the overpressure relief valve according to the
test procedure below.
5.9.4 Overpressure Relief Valve Lift Check/
Setting
Tools required:
Adjustable first stage scuba regulator or controlled
adjustable pressure source
Intermediate pressure test gauge
Torque wrench
1/2” open-end wrench adapter for torque wrench
1/8” Allen wrench
HP air source {SCUBA tank) with at least 500 p.s.i.g.
(34.4 bar).
Mild dish soap
The purpose of lift checking the overpressure relief valve
is to ensure it operates properly, allowing excess pressure
to escape in the event the first stage develops a slight leak.
Without the overpressure relief valve, high-pressure gas
will continue to increase until the emergency supply hose
ruptures, possibly causing injury and a complete loss of
the Emergency Gas System (EGS).
WARNING
Ensure the overpressure
relief valve is only installed in a low-pressure
port of the first stage
regulator. Installation in
a high-pressure port will
lead to loss of EGS supply and possible
serious personal injury if the valve fails.
This procedure explains the steps necessary for readjusting the overpressure relief valve after it is cleaned,
overhauled or any time the valve is tested.
NOTE:The overpressure relief valve is lift checked
and/or adjusted using an adjustable first stage regulator,
equipped with a low-pressure test gauge, which is used
for adjusting the intermediate pressure of scuba regulators. The check/adjustment can be performed using
a standard scuba test stand, or a gas control console,
using air or mixed gas with an oxygen content below
23% by volume.
WARNING
Do not use oxygen, or
mixed gas containing
more than 50% oxygen by
volume, for lift checking
the overpressure relief
valve. The use of oxygen,
or mixed gas, in a highpressure supply system not designed and
cleaned for oxygen service, can result in
a fire or explosion causing serious injury
or death.
If a first stage scuba regulator is used, it must be able
to be adjusted to the desired lifting pressure. The pressure gauge should be compared to a gauge of known
accuracy.
NOTE:If the Allen screw on the overpressure relief
valve hex nut is rotated too far, too fast, the overpressure relief valve will pop open. This could possibly
require the air to be secured at the cylinder or supply
source to reset the seat before the adjustment can be
accomplished.
NOTE: The overpressure relief valve can be installed
in any first stage regulator, providing the first stage
has an intermediate setting of 135 - 165 p.s.i.g. (9.3
– 11.4 bar).
1) Install the P/N 200-017 overpressure relief valve
into a low-pressure port on an adjustable 1st stage
regulator, using 20 inch pounds torque. Or install on
the scuba test stand.
2) Install the intermediate pressure gauge in one of the
low-pressure ports of the first stage regulator.
3) Install the 1st stage regulator on the cylinder. Ensure
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the relief valve and intermediate pressure gauge are
attached to low-pressure ports.
4) Wet the relief valve with soapy water to help indicate
gas flow
5) Slowly bring up air pressure while watching the
intermediate pressure gauge until the pressure gauge
indicates 180- 200 p.s.i.g. (12.40-13.78 bar). If the relief
valve starts venting at a pressure below 180- 200 p.s.i.g.
(12.40-13.78 bar), secure the air supply and adjust the
adjustment screw (1) in (clockwise) 1/8th turn. Slowly
bring up pressure and recheck.
If, after cleaning, the problem persists, replace the soft
seat and spring and retest the unit. If the seat continues
to leak, then replacement of the complete valve will
be necessary.
The purpose of lift checking the valve is to ensure
the relief operates properly allowing excess pressure
to escape in the event the first stage develops a slight
leak. This procedure also explains the steps necessary
for readjusting after cleaning or overhaul.
Continue this procedure as necessary until the relief
valve consistently vents at a pressure between 180- 200
p.s.i.g. (12.40-13.78 bar). If the valve does not start venting when the gauge reads 200 p.s.i.g. (13.78 bar), slowly
back out on the adjustment screw (counter clockwise)
until the valve starts venting, forming bubbles in the
soap solution.
6) After the valve has been adjusted, adjust the 1st
stage regulator intermediate setting to 135 p.s.i.g.
(9.3 bar), re-wet the valve, then slowly increase the
intermediate pressure on the 1st stage regulator one
last time to recheck the lift pressure. The valve should
start forming bubbles or venting at between 180- 200
p.s.i.g. (12.40-13.78 bar).
7) After final lift check reset the regulator to the appropriate over bottom setting. Remove the intermediate
pressure gauge.
TROUBLESHOOTING
Problem: Valve pops open and will not stop flowing:
Check: If while setting the overpressure relief valve
the valve pops open and will not stop flowing, secure
the air supply valve and allow the valve to reseat. Try
the procedure again, ensuring that the supply valve is
only slightly cracked open, allowing full test pressure
but minimizing high flow potential.
Problem: After resetting the first stage to 135 p.s.i.g.
(9.3 bar), the valve continues to leak:
Check: This indicates the valve body, seating surface
or the soft seat is either dirty or damaged. Usually,
cleaning both the metal body, seating surface in the
valve body and the soft seat will fix the problem.
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Chapter 6
Frame And Lens Repairs
6.1 General Information
All maintenance on the frame of the EXO Full-Face
mask can be accomplished with common hand tools.
6.2 Lens Replacement
Tools required:
Dow DC-111 or similar silicone grease
7/64" Allen head wrench, flat blade screwdriver, torque
screwdriver.
6.2.1 Lens Removal
1) Use a 7/64" Allen head wrench to remove the two
screws and washers from the sides of the lens clamp.
Remove the Nylon lock nuts if they are loose in the
frame.
Remove the screw and washer from the front of the
lens clamp in the nose area.
2) Remove the screw and washer from the front of the
lens clamp in the nose area.
3) Separate the lens clamp from the mask frame and
mask seal.
4) Carefully remove the old lens from the mask seal
by sliding the lens down enough to clear the top of
the lens clamp (which is part of the frame). Remove
any silicone from the rubber channel in the mask seal.
To remove the lens, you must remove the two screws
at the sides of the lens clamp.
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Nut
Mask Seal
Mount
Nut
Buckle
Cap
Buckle
Screw
Regulator
Assembly
Comm
Plug
Spider
Nut
Clamp
Lens
EXO Lens System Blowapart
Screw
Screw
6.2.2 Lens Installation
1) The top lens clamp (which is part of the frame) has
flats that will hold the Nyloc lock nuts in place. If the
locking feature of this nut is worn out or no longer
works, these nuts must be replaced. DO NOT use
any chemical locking liquids anywhere on the mask.
These chemicals can attack and damage the mask
frame material.
WARNING
DO NOT use any chemical locking liquids
anywhere on the mask. These chemicals
can attack and damage the mask frame
material. This could cause the frame to
fail without warning.
66
Do not use ANY
chemical locking
liquids anywhere on
the mask!
Install the nuts in the upper lens clamp part of the
frame, carefully using needle nose pliers if needed.
Be sure they are positioned properly and securely. Do
not squeeze them too tightly or you may damage the
plastic shelf where they seat.
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Adjust the seal around the bottom of the lens.
Apply silicone grease to the mask seal.
2) Place a bead (approximately 1/8 inch diameter)
of Dow DC-111 Lubricant or similar silicone grease
across the entire top lens groove of the main mask
seal. It should start at approximately 3/4 inch below
the top lens clamp corners and go to the same spot on
the opposite side.
3) With the word TEMPERED facing out, hold the
lens up slightly at an angle and begin to install the right
side of the lens rim into the channel of the rubber on
the mask seal. Make sure that the mask seal is seated
in the mask frame correctly.
Start installing the lens slightly below the top lens
clamp for clearance when installing. Push the lens
to the side far enough to make the plastic clamp flex
slightly outward allowing the lens to be fitted into place
on the other side.
Install the right side of the lens rim into the channel
of the rubber on the mask seal.
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved.
4) Lower the left side of the lens towards the opposite
side of the mask rubber and clamp. Just before they
meet, grab the edge of the rubber channel and pull
it up slightly above the outer edge of the upper lens
clamp and press the lens into the rubber channel and
then into the upper lens clamp.
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Use a flat blade screwdriver to keep the mask seal
from pinching as the lens clamp is tightened.
Install the lens clamp that connects to the mask frame.
5) Push the lens up and into the rubber channel of the
mask seal and top of the upper lens clamp. Hold the
lens in position and fit the bottom channel of the rubber
mask seal on the bottom edge of the lens.
6) Once the lens is properly seated in the mask seal
and upper lens clamp, install the lower lens clamp.
Place the two ends of the bottom of the clamp onto
the outside of the rubber channel to hold the rubber
in position. Work the clamp onto the mask starting at
the nose. Make sure the rubber is seated evenly onto
the lens rim and into the lens clamp.
7) Push up on the area under the nose screw to align
the nose screw hole in the lens clamp with the hole in
the rubber and the thread insert in the plastic rim on
the lens. Insert the slotted screw and the washer here
and tighten only about 3 or 4 turns. Do not snug or
finish tightening the screw at this time!
CAUTION
DO NOT OVER TIGHTEN THE LENS MOUNT
SCREWS. Over tightening can cause damage to both the lower lens clamp and the
upper clamp/frame requiring replacement.
68
Check the seating of the mask seal and lens clamps
on the inside of the mask.
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8) Pull up on the lower lens clamp and install the Allen head screws through the clamp until they thread
into the nuts in the upper lens clamp part of the frame.
Lightly tighten these screws, alternately tightening
from side to side so the clamp is drawn up evenly, but
do not tighten all the way.
9) Finish tightening the nose screw using an inch pound
torque screwdriver set at 6 inch pounds.
10) Finish tightening the Allen head clamp screws.
Use a flat blade screwdriver very gently if needed to
keep the rubber from pinching between the two clamps.
Tighten the clamps until they bottom against each other.
Do not over tighten.
11) Check the inside top of the glass where it meets the
rubber and make sure everything is properly seated.
Check both sides of the lens and seal. If any excess
silicon grease has squeezed out, remove it.
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved.
Check the gap on both sides of the lens to be sure it
is equal.
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6.3 Buckle Replacement
Note: The "T" Nuts are made with a special one
time thread locking feature. If the buckles are to
be removed the "T" Nuts must be replaced.
Note: By shortening the short leg of the 1/8" Allen
wrench (see photo) this job is made much easier.
6.3.1 Buckle Removal
1) Remove the spider (Head harness)
2) Use a 3/16" Allen wrench to remove the "T" nuts
and a 1/8" Allen wrench to remove the screws that hold
the buckles and buckle caps on.
6.3.2 Buckle Installation
1) Install all the washers onto the screws with the
sharp side of the washer towards the head of the screw.
2) Fit the buckles up into the bottom side of the buckle
caps. Ensure that the buckles are facing the right way.
The folded piece of the buckle assembly with the mounting hole through it has a loop in it. This loop should fit
into the space on the bottom side of the buckle caps.
WARNING
If the “T” nuts are not properly installed
there is the possibility the screw will become loose and fall out. This will result in
the loss of an entire buckle assembly and
could cause the mask to flood if enough
buckles are lost. Flooding the mask could
lead to drowning and death.
Become familiar with the way the washers
should fit to the “T” nuts. When properly
installed the washers will fit around the
minor diameter of the “T” nut when properly in place. The washer MUST NOT be
captured between the head of the Allen
screw and the end of the “T” nut when
tightened.
3) Fit the “T” nuts through the top sides of the buckle
cap and through the mounting hole in the buckle.
4) Apply a small amount of silicone grease to the hole
on the tab of the mask seal.
Nut
Mask Seal
Buckle
Cap
Buckle
Screw
EXO Buckle Diagram
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Lightly lubricate the screw hole on the spider tab.
Use a 3/16" Allen wrench to tighten the "T" nuts.
seal, then through the mask frame. Insert the 3/16"
Allen wrench in the “T” nut and hold the assembly in
place on the frame.
7) Take the Allen screw with a washer on it on the
1/8" Allen wrench and hold it up against the back side
of the “T” nut. Turning the 3/16" Allen wrench and
the “T” nut, thread the screw into the "T" nut. Tighten
the screw and "T" nut. Once again make sure that the
washer is correctly positioned on the "T" nut and that
it is not captured.
8) Repeat steps 3 thru 7 for all the buckle assemblies.
Insert the screw through the mask frame.
5) Place an Allen screw with a washer on it onto the
shortened leg of the 1/8" Allen wrench.
6) Take one entire assembly of “T” nut, buckle cap,
and buckle and press the end of the “T” nut through
the hole on the back side of one of the tabs on the mask
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6.4 Replacing the Face Seal or Frame
The face seal should be inspected prior to every dive
to check for punctures, tears or signs of cracking. A
torn or cracked face seal may cause the mask to free
flow and/or flood. If the face seal is damaged, it must
be replaced. This can be a difficult procedure.
It is recommended that this procedure be done by a
factory trained KMDSI dealer. If you are going to
attempt this procedure, read and understand all
previous sections of this chapter before you start.
The EXO Tool Kit, Deluxe KMDSI Part #325-650 is
required to do this procedure.
Tools Required:
3/16 inch Allen wrench, 1/8 inch Allen wrench, EXO
Tool Kit, Deluxe
6.4.1 Face Seal Removal
1) If you are using communications, remove the communications module, microphone and earphones. See
the chapter on communications.
2) Release the spider from the buckles and remove.
3) Remove the regulator assembly, per this chapter.
4) Remove the lens, per this chapter.
5) Remove the buckles and buckle caps, per this chapter.
6) Separate the mask seal from the mask frame.
6.4.2 Face Seal Installation
1) Put the mask seal into the frame. Seat the lens seal
area of the mask seal into the upper lens clamp part of
the frame. Seat the regulator and comm module areas
of the mask seal in the correct spots on the frame.
2) Install the regulator assembly, per this chapter.
3) Install the lens, per this chapter.
4) Install the buckles and spider, per this chapter.
5) Install the communications module. See Chapter 7.
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Chapter 7
Communications
The EXO may be ordered either with no comms or
with one of three different communications modules.
They are: Binding Posts for bare wire connection,
Waterproof Connectors for hard wire communications, and Wireless communications.
In surface supplied diving the most commonly used
types of connectors are the binding posts and the waterproof connectors. Waterproof connectors provide
better communications. In addition, if you are diving
in salt water, waterproof connectors will extend the life
of the communications wire in your umbilical.
7.1 Bare Wire Binding Posts
To connect bare wires to binding posts, be sure you have
a sufficient length of clean, bare wire exposed. If the
wire is covered with corrosion clean it until the shiny
wire is exposed or cut it back and expose new wire.
1) Twist the wire strands in each individual wire until
Coat with a thin coat of solder to prevent fraying.
they are wound tightly together. Coat these with a thin
coat of solder to prevent fraying.
2) Unscrew each of the binding post nuts until the hole
in the shaft of the post is exposed.
3) Insert one soldered wire into each of the holes in
the binding posts. The wires should stick out of the
hole of each post, but should not touch each other. If
the wires touch, you will create a “short” and there
will be no communications between the diver’s mask
and the top side communication box.
4) Tighten each of the binding post nuts until snug. Do
not overtighten.
Communications module with microphone cup for
original EXO.
5) Test the communications system and ensure that it
is in proper working order.
7.2 Waterproof Connector (WPC)
Waterproof connectors are a little more expensive than
bare wire posts, but they provide better communications,
the possibility of a 4 wire system, and will extend the
life of the diver’s umbilical communications wire. Salt
water entering the bare wire system will lead to corrosion of the wires and possible failure of the system.
Communications module with cap for EXO BR.
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved.
Waterproof connectors are rugged but require a bit
more care in handling than binding post connectors.
If you are careless in handling a waterproof connector
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you may cause it to fail and they can not be repaired.
Most waterproof connector manufacturers recommend
that you lubricate the connections using silicone grease.
1) To connect the male and female portions of the
waterproof connectors, align the key on the male connector with the yellow mark on the female connector.
2) Press the two connectors together until you hear a
The communications system should always be tested
prior to the diver entering the water.
EXO STANDARD or BR Module Assembly With Waterproof Connector
distinct “pop”, which is the air escaping from between
the two connectors, creating a seal.
3) Tape the two connectors with a bit of electrical tape
to prevent them from pulling apart.
4) Test the communications system and ensure that it
is in proper working order.
Align the key on the male connector with the yellow
mark on the female connector.
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7.3 Wireless Communications
The EXO mask may also be used with wireless communications. There are several manufactures of these
units, OTS (Ocean Technology Systems) and DiveLink,
just to name a few. Read and follow the manufacturers'
instructions for these units.
Wireless systems are usually only employed by free
swimming SCUBA divers. Wireless systems allow
the diver to swim unrestricted by any lines or tethers.
However, if you are using the EXO in the surface supplied mode it is usually more effective and reliable to
use a hard wire system.
Wireless systems are used in many different types of
diving. Some examples include search and rescue, research diving, and SCUBA instruction. With a wireless
system it is possible to communicate both diver-to-diver
and/or diver-to-surface.
The communications system should always be tested
and any problems solved or adjustments made prior
to the diver entering the water. Procedures may vary
between the makers of the top side communication
boxes. Follow the manufacturer's instructions on how
to test these units.
Wireless communications are strongly recommended
whenever you are diving in the scuba mode with a
full-face mask.
WARNING
The waterproof case for your wireless
communications unit should only be attached to your scuba backpack, never
to your weight belt. In the event your belt
must be dropped the belt must have a clear
drop path and must not be connected to
any other piece of gear.
If this procedure is not followed the weight
belt and wireless electronics case will be
attached to the mask by the connecting
wire. This could lead to drowning.
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7.4 Removing the Communications
Module
After each day of diving, the entire mask communications system should be removed, cleaned, and allowed
to dry.
1) First remove the communications mounting ring by
unscrewing it.
2) Reach inside each earphone pocket, grasp the earphone and remove it.
CAUTION
Do not remove the earphones by pulling on
the wires. This may damage their interior
connections.
CAUTION
Do not apply any pressure to either the
penetrator, or the communications posts,
for removal. This could possibly damage
the unit.
Remove the outer earphone covers and allow all the
parts to dry.
Waterproof Connector
Pigtail
Comm Mount
Nut
Earphone Assembly
Right
Earphone Assembly
Left
Binding Post
Terminals
Wiring Harness
Microphone
EXO Mask Communications
Components
Communications
Module
76
Rubber Cover
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On the EXO original, make sure the microphone cup
is positioned correctly.
5) Screw the comm module mount nut back onto the
comm module and tighten.
6) Insert the earphones in their pockets. Using a pump
spray type of silicone, a light coat on the outside of the
earphone covers helps the earphone assembly to slide
into the pocket easier.
7) Tuck any excess wires behind the edge of the mask
seal.
Make sure the microphone cup in the EXO Original
is positioned correctly.
3) In the EXO Standard or Balanced remove the microphone from the oral nasal. Once again do not pull
on the wire as this can damage the connection.
4) The entire communications assembly can now be
separated from the mask. The module should be pushed
to the inside of the mask by applying pressure to the
flat angle area on the exterior of the comm module.
5) Remove the outer earphone covers, and on the EXO
Original the microphone cup, and allow all the parts
to dry.
7.5 Installing the Communications
Module
If you are installing communications into a mask that
did not originally come with communications, the back
side of the microphone cup on the oral nasal may need
to be trimmed out. If it is the newer version, simply
remove the plastic plug.
CAUTION
Avoid spraying aerosolized silicone spray
on any of the plastic parts of the mask.
Certain chemicals used to propel silicone
spray from the can may damage the plastic
components of the mask. Use silicone in a
bottle with a manual pump or a very light
application of silicone grease.
8) Mount the microphone back into the oral nasal (EXO
Standard or BR).
9) Test to ensure that the communications module is
in proper working order.
10) Masks not using communications systems should
be fitted with an oral nasal microphone cup plug.
KMDSI oral nasal plug, part # 320-001 is available
for this purpose.
1) Ensure that the mask seal is correctly seated in the
frame. This is very important as the mask seal also acts
as the seal for the communications module.
2) Reassemble the earphone covers and the microphone
cup (EXO Original).
3) If the comm module is equipped with a waterproof
connector, insert the waterproof connector back through
the mask seal and frame from the inside of the mask
4) Work the comm module into the mask seal from
the inside until it is properly positioned and seated.
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7.6 Earphone and/or Microphone
Removal
1) Remove the communications assembly from the
mask.
2) Remove the comm module cover (EXO Standard
or EXO BR).
3) Using a small flat blade screwdriver, carefully scrape
out the waterproof coating in the slots of the screws in
the comm module and remove the screws and washers.
Take note of where all the wires are connected, it
will help when reassembling the unit.
nect the wires into the comm module using the
screws and washers.
4) Test the communication assembly.
5) Once the comm assembly has been tested and is
in working order, paint a light coat of RTV silicone
sealant onto the screws, washers, and terminals to
waterproof them.
6) Reinstall the comm module cover (EXO Standard or EXO BR).
4) Carefully remove the wires from the module.
7.7 Earphone and/or Microphone
Installation
1) Test the assembly, earphone or microphone, to
ensure that your components are functioning properly before installation into the comm module.
2) Insert the wires into the comm module one at a
time in the correct order (see above).
3) Use the correct wiring diagram at the end of this
chapter for your communications set up to recon-
Microphone
Wire
Left Earphone on
this side (Long Wire)
Right Earphone on
this side (Short Wire)
Insert the wires into the comm module one at a time in the correct order
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7.8 Removing the Waterproof
Connector (WPC)
7.10 Removing the Binding Posts
1) Remove the communications assembly from the
mask.
2) Remove the comm module cover (EXO Standard
or EXO BR).
3) Remove the earphones and microphone connections
from the comm module.
4) The WPC mount nut on the inside of the comm
module should be held so that it won't turn. Use a 3/4"
open end wrench on the exterior WPC packing and
unscrew the WPC assembly from the comm module.
1) Remove the communications assembly from the
mask.
2) Remove the comm module cover.
3) Remove the earphones and microphone from the
comm module. Take note of where all the wires
are connected. This will help when reassembling
the unit.
5) Remove the WPC mount nut from inside the comm
module.
7.9 Installing the Waterproof
Connector (WPC)
1) Put a small bead of RTV silicone sealant around the
top part of the threads on the WPC packing where it
rests against the comm module to form a seal between
the WPC and the comm module.
2) Put the WPC mount nut in the comm module and
hold it up against the hole in the comm module.
3) Feed the wires from the WPC through the hole in
the module and through WPC mount nut. Screw the
WPC assembly into the comm module and tighten.
Clean any excess RTV from around the WPC packing.
4) Feed the earphone and microphone wires into the
comm module. Make sure they are in the right order.
(Fig. 6.)
5) Follow the appropriate wiring diagram and reconnect the wires.
6) Test the communication assembly.
7) Once the comm assembly has been tested and is
in working order, paint a light coat of RTV silicone
sealant onto the screws, washers, and terminals to
waterproof them.
8) Reinstall the comm module cover (EXO Standard
or EXO BR).
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved.
Use a metal pick or a small stiff piece of wire inserted
in the binding post to keep it from spinning.
4) Use a metal pick or a small stiff piece of wire
and insert it through the wire connection hole in the
binding post. This will help you hold on the post
and either spin it or keep it from spinning. Also, use
a 3/8" open end wrench on the binding post mounting nuts on the inside of the module and unscrew
the binding posts.
5) Remove the nuts, washers, and wire harnesses
from the inside of the comm module. Take note
of where all the wires are connected, it will help
when reassembling the unit.
7.11 Installing the Binding Posts
1) Put a bead of RTV silicone sealant around the
bottom of the threads and on the bottom of the binding post body.
2) Insert the binding post into one of the holes in the
comm module.
3) Put one end of the wire harness on the end of the
post, followed by the washer, and nut. Tighten the
binding post into the comm module. Repeat for the
other post.
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4) Feed the earphone and microphone wires into
the comm module. Make sure they are in the right
order. Refer to the Installing the Earphone and Microphone section of this chapter.
5) Follow the appropriate wiring diagram to reconnect the wires.
6) Test the communication assembly.
7) Once the comm assembly has been tested and is
in working order, paint a light coat of RTV silicone
sealant onto the screws, washers, and terminals to
waterproof them.
8) Reinstall the comm module cover (EXO Standard or EXO BR).
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7.12 Waterproof Connector (WPC)
Assembly Rebuild
10) Solder terminals on to the end of the wires.
1) Remove the waterproof connector (WPC) assembly
from the comm module.
11) Test WPC assembly with a multi-meter if possible
to ensure that all connections are good. Reinstall WPC
assembly in comm module, per this chapter.
2) Cut off the terminals or "sweat " them off with a
soldering iron if you are going to reuse them.
3) Unscrew the packing gland from the pigtail nut. Take
off the packing gland, rubber seal, packing washer and
pigtail nut. Note the position of the rubber seal and
the packing washer and the directions that they face.
4) Discard the old WPC.
5) On new WPC's the black casing may need to be
stripped back 1 1/4" from the end of the wires. The
tips of the wires usually come already stripped and
dipped in solder. If not, strip the end of the wires 1/4"
and solder the ends to prevent fraying.
6) Lightly grease 2 " of the black casing with silicone grease to help slide the pigtail nut on. Slide
the pigtail nut on, making sure it faces in the correct
direction.
7) Position the packing washer 2 1/4" from the end of
the wires and facing in the correct direction. Put the
rubber seal on also facing in the correct direction and
slide it up against the packing washer.
8) Slide the packing gland on up against the rubber
seal, making sure it is facing in the correct direction.
Try not to move the position of the packing washer.
9) Screw the packing glands and pigtail nut together
and tighten.
Packing Washer
Waterproof Connector Assembly
Rubber Seal
Mount Nut
Pigtail Nut
Waterproof Connector
Packing Gland
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7.13 Waterproof Connector (WPC) Pin
Diagrams
White Wires, Earphones
Microphone
The view in these diagrams is looking straight at the
pins on the WPC. The large pin is at the top.
Black Wires, Earphones
Microphone
7.14 Post Dive Maintenance
If your mask is equipped with any type of communications, post dive maintenance on the mask and communications module must be done after each days dive. The
post dive procedures may vary between manufacturers,
depending on which communication module you are
using. Follow the manufacturers instructions on post
dive maintenance. The following is the recommended
post dive maintenance procedures for the KMDSI
communications modules.
2 Pin Waterproof Connector
White Microphone Wire
Black Earphone
Wires
Black Microphone Wire
1) Remove the communications from the mask.
2) Lightly rinse the assembly with fresh clean water. Do
not immerse the entire assembly under water and try
to keep the water out of the earphone covers and from
under the module cover. The microphone can get wet.
White Earphone Wires
4 Pin Waterproof Connector
3) Dry the assembly off. Open the earphone covers
and take the module cover off and let everything dry
on the inside.
4) Once everything is dry, reassemble the earphone
covers and reinstall the module cover.
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Communications Module Assembly Wiring Diagrams
Screws and Washers
Wire Harness
Black Earphone Wires
Black Microphone Wire
Wire Harness
Red Earphone Wires
White Microphone Wire
Binding Post
Wire Harness
Binding Post
Wire Harness
Binding Posts
Screws and Washers
Black WPC Wire
Black Earphone Wires
Black Microphone Wire
White WPC Wire
Red Earphone Wires
White Microphone Wire
2 Pin 2 Wire
WPC Assembly
2 Pin 2 Wire, Waterproof Connector (WPC)
White WPC Wire
Microphone Wire
Black WPC Wire
Microphone Wire
Green WPC Wire
Black Earphone Wire
Red Earphone Wire
Red WPC Wire
Black Earphone Wire
Red Earphone Wire
4 Pin 4 Wire
WPC Assembly
4 Pin 4 Wire, Waterproof Connector (WPC )
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Appendix
Breathing Gas Requirements
EXO Balance Regulator Full-Face Mask
B
TE
ST E D C O M M
E
-
P
™
GE
AR - DIV
EL
A
8.5 CE Approved
The EXO-BR is CE Approved.
8.5.1 CE Approved
The EXO Full Face Mask 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 15333-1:2008/AC:2009 (Class C).
It is fully CE marked with demand regulator EXO-26
BR_Balanced Regulator (1st stage pn 305-161 and
2nd stage pn 305-040).
Category of PPE: III
The EXO Full Face Mask has been
tested with air and CE certificates for
use with air up to 50 meters.
Compressed air must been compliant
with the EN 12021.
Diving in cold water, i.e., at temperatures below 50 degrees F (10°C), may
subject the diver to severe respiratory
heat loss. This may lead to a decrease
in body core temperature also known
as “hypothermia.” Hypothermia is
extremely dangerous and can lead to
a loss of reasoning ability, decreased
manual dexterity, uncontrollable shivering, unconsciousness, and death.
All the tables reporting the technical
data and the pressure of use are relative to compressed air.
The cage code for identifying KMDSI products for
U.S. government purposes is 58366.
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved.
LY RATED
B WARNING
B WARNING
8.3 Cage Code
IAL
NG
8.2.1 EXO-BR® Regulator
The EXO-BR® regulator on the EXO Full-Face
Mask offers high performance. The regulator has
been tested at Dive Lab at Panama City, Florida. It
meets or exceeds all current U.S. Navy and European diving standards.
8.2.2 Minimum Operating Temperature
The minimum operating temperature recommended
for this regulator for surface supplied diving is 33 degrees F (~1°C) and for scuba is 37 degrees F (~3°C),
only in regards to regulator performance. At the time
of this writing, no hot water shroud is available for
this mask for heating the diver’s breathing gas
These masks meet or exceeds all
standards established by Dive Lab
of Panama City, Florida, and is CR
(Commercially Rated) marked.
RC
ESSIONAL D
IV
I
8.2 Regulator Performance
8.4 CR Standards
F
RO
If you have any questions regarding proper set-up,
operation, or maintenance of your Kirby Morgan
mask contact KMDSI (850) 928-7772 or at kmdsi@
KirbyMorgan.com or Dive Lab Inc. (850) 235-2715
or at Divelab@aol.com. There are also detailed
checklists for the set-up and maintenance of your
mask on the Dive Lab web site at www.divelab.com.
8.5.2 Notifying Body
The Notifying Body is
Eurofins-Modulo Uno
S.p.A.
Address:
Via Cuorgne,
21-10156 Torino,
ITALY
Identification number: 0477
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8.5.3 Notifying Body
In the mark the data reported are the following:
DANGER
Decompression diving always involves the
risk of decompression sickness. Omitted
decompression due to a loss of the breathing
gas supply or other accidents can cause serious injury or death. Use of a Kirby Morgan
helmet or mask cannot prevent this type of
injury.
B CAUTION
The user cannot:
• Remove the mark from the BR
regulator;
• Modify or counterfeit the data
reported on the mark.
B CAUTION
1. The name and the address of the manufacturer;
2. Harmonized reference standard: EN 250:2000, EN
250/A1:2006 and EN 15333-1/AC:2009;
3. CLASS C = NO protection;
4. PPE model;
5. Serial number (laser etched on the EXO Full Face
Mask frame);
6. CE marking:
;
7. Notifying Body number.
The mark shall be visible and legible
throughout the life of the PPE. If the
mark deteriorates or is not legible the
user should contact the manufacturer.
8.6 Operational Specifications &
Limitations for Surface-Supplied
Diving
-Umbilical minimum I.D. 3/8” (9.5
mm) of not more than two sections,
total length not to exceed 600 feet
(183m).
This mask meets or exceeds all requirements of NPD,
HSE (UK), US Navy and US Coast Guard. It is CE
certified and CR rated by Dive Lab, Panama City,
FL, USA.
Work Rate Expressed as Respiratory Minute Volume (RMV)*
Work Load
RMV
Cubic Feet/Minute Equivalent Land Based
(CFM)
Exercise
Rest
7-10 RMV
0.2 - 0.35 CFM
Light Work
10-20 RMV
0.35 - 0.7 CFM
Walking 2 miles per hour
Moderate Work 20-37 RMV
0.7 - 1.3 CFM
Walking 4 miles per hour
Heavy Work
37-54 RMV
1.3 - 1.9 CFM
Running 8 miles per hour
Severe Work
55-100 RMV 1.94 - 3.5 CFM
* source: U.S. Navy Diving Manual
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8.6.1 Using the EXO-BR Regulator with a
Low Pressure Compressor Supply
The EXO-BR Regulator Low Pressure Compressor
Supply Pressure Requirements table in this manual
are designed to assist you in selecting the proper
compressor for the depths at which you plan to work
and for the work load at which you will be working.
In physiological terms, work load is normally defined
in terms of exercise rate. Exercise rate is normally
determined by heart rate and may also be defined by
your breathing rate. The higher your heart rate and
the higher your rate of breathing, the harder you are
working. For a highly fit diver, the limiting factor
in how hard you can work underwater is how much
breathing gas your mask will supply.
• When using HP supply systems (Control Consoles)
use the recommended pressures for depth as listed in
the table for High Pressure Regulators Settings found
in this chapter. For best overall performance avoid using pressures excessively higher than what is required
for depth especially if diving shallow.
For practical purposes, the U.S. Navy defines breathing work rates in terms of “RMV” which stands for
Respiratory Minute Volume.” RMV is defined as the
amount of breathing gas that flows in and out of your
lungs in one minute.
B WARNING
Users should ensure that the compressor or supply
system meets both the supply pressure and output
volume required for the deepest anticipated depth
and ventilation rate. Below is the formula used for
computing the volume of air being used at a given
ventilation rate at depth.
Note: This is the bare minimum. As a safety margin, it
is best to plan on an additional 10%-20% of breathing
gas to ensure the supply system can keep up.
{(Depth + 33) ÷ 33} × RMV} × .10 or .20 safety
margin.
Best Practice:
• When using a LP compressor always base the output
pressure on the lowest pressure during compressor
cycling.
• Complete a flow test of the compressor / air system
and all umbilicals at least once a year and/or whenever
in doubt as to the capability.
• Always take the standby diver into consideration
when planning air usage.
• Always allow for at least 10-20% greater volume
than what is needed for the maximum ventilation
anticipated.
• Never use less than 40 RMV for planning purposes.
• Always dive with a fully functional man worn emergency gas supply system (EGS) of sufficient capacity
based on the hazards of the task, have the cylinder
valve open and the emergency valve shut.
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved.
If using umbilicals longer than 600 feet, or umbilicals
with an internal diameter less than 3/8” (9.5mm), or
other configurations not mentioned, E-mail or call
KMDSI or Dive Lab, Inc., for further guidance and
information.
8.6.2 Using the EXO-BR Regulator LowPressure Compressor Supply Pressure
Requirements Table
The EXO-BR Regulator® Low-Pressure Compressor Supply Pressure
Requirements tables presented in
this manual are intended for use with
properly adjusted and maintained
KMDSI® EXO Balanced Regulator
Full-Face masks only. None of the
KMDSI® supply tables have been
evaluated on other makes of masks
and should not be used with other
manufacturers’ helmets or masks.
B WARNING
To properly supply the diver with
breathing air, the mask as well as
the umbilical and associated supply
system must be properly configured,
maintained, and adjusted.
To use this table, you must know your compressor’s
maximum pressure output, the diver’s maximum
planned depth, the volume of gas the compressor is
capable of pumping, and the diver’s anticipated work
load. These tables are NOT designed for use with
the Kirby Morgan SuperFlow 350 or 450 regulators.
SCFM stands for “Standard Cubic Feet Per Minute”
and is a measure of the volume of air the compressor delivers. This measurement is made at sea level.
SLPM is an abbreviation for Standard Liters Per
Minute and is the metric equivalent of SCFM.
Example #1: You are using a 5120 compressor with
a maximum output pressure of 200 p.s.i.g. A Quincy
5120 compressor is designed to deliver 88.5 cubic
feet of free air at 200 p.s.i.
You know you will be doing a long job,
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positioning sand bags for a pipeline crossing at a
depth of 160 FSW. Look in the table at the left hand
column and find the maximum pressure output for
your compressor, i.e, 200 p.s.i. You will see that at
200 p.s.i.g. the compressor will supply sufficient air
to maintain 40 RMV at depths down to 220 FSW,
with a sufficient volume of air.
Example #2: You plan to use a 325 compressor with
a maximum output pressure of 150 p.s.i.g. A Quincy
325 delivers 19.20 cubic feet of free air at 150 p.si.
To carry sandbags for a pipeline crossing at a depth
of 160 FSW, although the 325 would provide sufficient air for the diver to perform work at 40 RMV, it
would not provide the recommended safety margin
of 10%-20%. If your work load increased to 50 RMV,
the compressor would not be sufficient to support that
work load and would leave you feeling starved for air.
Remember that if a decompression chamber is on the
same circuit as the diver, the diver will be starved
for air if the chamber is blown down while the diver
is in the water. Whenever possible, there should be
at least one air source devoted to diving operations
and a separate air source used solely to operate the
decompression chamber.
Once the diver begins to consume air faster than the
compressor can supply it, the diver will feel starved
for air. This is a very dangerous situation underwater.
B WARNING
It is important for the user/diver to
take excessive currents into consideration. The exhaust system on the
EXO-BR® Regulator will help prevent
water intrusion when diving in heavy
currents. The EXO-BR® exhaust system does not limit the diving depth.
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.
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EXO-BR Regulator® Low-Pressure Compressor Supply Pressure Requirements Table*
Supply Pressure Surface
RMV
Maximum Recommended Required
Required
Gauge Reading
(Respiratory
Depth
SCFM**
SLPM**
Minute Volume)
FSW
MSW
90 P.S.I.G . (6.21 BAR)
40 (heavy work)
50 (heavy work)
62.5 (severe work)
75 (severe work)
104
76
61
50
32
23
18.8
15.4
7.0
7.0
7.5
8.0
198
198
212
227
100 P.S.I.G. (6.9 BAR)
40 (heavy work)
50 (heavy work)
62.5 (severe work)
75 (severe work)
108
90
75
59
33
27
22.9
18
7.25
7.9
8.7
8.9
205
223
246
252
110 P.S.I.G. (7.59 BAR)
40 (heavy work)
50 (heavy work)
62.5 (severe work)
75 (severe work)
117
100
83
68
35
30
25
21
7.7
8.6
9.3
9.7
218
244
263
275
120 P.S.I.G. (8.28 BAR)
40 (heavy work)
50 (heavy work)
62.5 (severe work)
75 (severe work)
127
113
93
75
38.7
34
28
23
8.2
9.4
10
9.7
232
266
283
275
130 P.S.I.G. (8.97 BAR)
40 (heavy work)
50 (heavy work)
62.5 (severe work)
75 (severe work)
145
125
106
85
44
38
32
26
9.1
10
11
11.36
258
283
311
322
140 P.S.I.G. (9.66 BAR)
40 (heavy work)
50 (heavy work)
62.5 (severe work)
75 (severe work)
160
135
114
92.5
48
41
35
29
10
11
12
12
283
311
340
340
150 P.S.I.G. (10.35 BAR)
40 (heavy work)
50 (heavy work)
62.5 (severe work)
75 (severe work)
170
149
126
105
52
45
38
32
10.5
11.7
13
13.3
297
331
368
377
The above values were derived from actual breathing simulator tests using an ANSTI wet simulator with 600’ long umbilical 3/8’’
I.D (9.5mm) at Dive Lab, Inc. The respiratory work rates and test procedures used are based on internationally recognized test
practices and procedures.
** includes a 20% safety factor
Note: Most sustained work rates by professional divers average between 20 to 40 RMV. When calculating supply requirements,
KMDSI® recommends using no less than 40 RMV.
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EXO-BR Regulator® Low-Pressure Compressor Supply Pressure Requirements Table*
Supply Pressure Surface
RMV
Maximum Recommended Required
Required
Gauge Reading
(Respiratory
Depth
SCFM**
SLPM**
Minute Volume)
FSW
MSW
160 P.S.I.G . (11.04 BAR)
40 (heavy work)
50 (heavy work)
62.5 (severe work)
75 (severe work)
186
157
134
112
57
48
41
34
11.3
12.2
13.4
14
320
345
379
396
170 P.S.I.G. (11.73 BAR)
40 (heavy work)
50 (heavy work)
62.5 (severe work)
75 (severe work)
203
170
143
121
62
52
43
37
12.2
13
14
14.9
345
368
396
422
180 P.S.I.G. (12.42 BAR)
40 (heavy work)
50 (heavy work)
62.5 (severe work)
75 (severe work)
219
180
158
130
67
55
48
39
13
13.7
15.4
15.7
368
388
436
445
190 P.S.I.G. (13.11 BAR)
40 (heavy work)
50 (heavy work)
62.5 (severe work)
75 (severe work)
220
192
165
141
67
58
50
43
13
14.5
16
16.8
368
411
453
476
200 P.S.I.G. (13.80 BAR)
40 (heavy work)
50 (heavy work)
62.5 (severe work)
75 (severe work)
220
205
174
147
67
62
53
45
13
15.3
16.7
17.4
368
433
473
493
210 P.S.I.G. (14.49 BAR)
40 (heavy work)
50 (heavy work)
62.5 (severe work)
75 (severe work)
220
214
186
159
67
65.8
56
48
13
16
17.6
18.5
368
453
498
524
220 P.S.I.G. (15.18 BAR)
40 (heavy work)
50 (heavy work)
62.5 (severe work)
75 (severe work)
220
220
194
165
67
67
59
50
13
16.3
18.2
19
368
462
515
538
The above values were derived from actual breathing simulator tests using an ANSTI wet simulator with 600’ long
umbilical 3/8’’ I.D (9.5mm) at Dive Lab, Inc. The respiratory work rates and test procedures used are based on internationally recognized test practices and procedures.
Note: Most sustained work rates by professional divers average between 20 to 40 RMV. When calculating supply
requirements, KMDSI® recommends using no less than 40 RMV. For more information, check the Dive Lab website,
www.divelab.com
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8.6.3 Using a High-Pressure Breathing Gas
Supply
High pressure (HP) control consoles are capable of
suppling air or mix gas at pressures and volumes
much greater than low pressure air compressors, and
are often preferred by military and scientific divers. HP air systems are often used as back up supply
for LP compressor diving.
When using HP air or mix gas systems, The regulator is normally loaded to 100-150 psig on the surface
and increased to the bottom setting as the diver descends or when the diver reaches the bottom. During
ascent the pressure is reduced to between 100-150
p.s.i.g. once the diver is shallower than 100 feet. A
high-pressure gas supply is typically used under the
following conditions:
• When the work load exceeds the capabilities of the
compressor to supply a sufficient volume and pressure of breathing gas, regardless of the depth.
• When the diver is using pre-mixed gas.
• As a back-up for a low-pressure compressor
• Any time a high-pressure supply is available
The regulator is loaded as the diver increasingly
descends and unloaded as the diver returns to the
surface. If the diver experiences a free-flow with his
regulator, when the bias adjustment knob is properly
set and the regulator has been maintained correctly,
the pressure setting on the high-pressure regulator
setting may be too high and may need to be decreased.
B WARNING
The demand regulator
and side block assemblies have a maximum
design pressure of 225
p.s.i.g. (15.5 bar) overbottom. Higher pressures could lead to
component failure and
serious personal injury.
B WARNING
Gas systems used to supply Kirby
Morgan helmets and masks must
be capable of supplying gas to the
diver at the required pressure and
flow rates as stated in the operational
specifications. The use of unregulated
gas sources is extremely dangerous.
The use of standard SCUBA type
regulators is unacceptable, as there
are no provisions for adjusting the intermediate pressure to the diver. Only
proven systems that allow for varying
the gas supply pressure to the diver
should be used for umbilical diving.
B WARNING
When the EXO FULL FACE MASK is
used for air diving in countries that
conform to CE regulations, it shall be
used to a maximum depth of 164 fsw
(50msw) I.A.W. EN15333-1.
The following table provides recommended pressures when using a high-pressure breathing gas supply and
dome loaded regulator. Generally speaking, the topside regulator should be set at 140 p.s.i.g. over bottom
pressure for optimum regulator performance.
Topside High-Pressure Regulator Settings for use with the
Kirby Morgan EXO-BR Regulator®
Depth
FSW
0-60
61-100
101-132
133-165
166-220
MSW
0-18
19-30
31-40
41-50
51-61
Regulator
Regulator
Setting P.S.I.G.
Setting BAR
Optimum Maximum Optimum
MaxiP.S.I.G.
P.S.I.G.
BAR
mum
BAR
140
200
9.7
13.8
165
220
11.4
15
190
250
13
17
275
300
19
20.7
300
320
20.7
22
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Appendix II
EXO Full-Face Mask Transport And Storage
9.1 Helmet Transport And Storage
• The kind of package for one EXO® FFM is a
cardboard box with cardboard inserts to stabilize the EXO® FFM
• The kind of packaging for two EXO® FFMs is
a cardboard box with air filled pillows to stabilize the EXO® FFM;
The weight of the box is usually:
• For 1 EXO® FFM is 8.3 pounds (3.77 Kg);
• For 2 EXO® FFM is 18.3 pounds (9 Kg);
The package dimension are:
• For 1 EXO® FFM is 12 × 10 × 12 inches (305 ×
254 × 305 mm);
• For 2 EXO® FFM is 26 × 13 × 13 inches (660 ×
330 × 330 mm);
• The EXO® FFMs are sent to dealers by plane
and truck. Depending on how the dealer wants
it sent.
Packaging Step 2
9.1.1 One EXO® Full Face Masks
Packaging Step 3
Packaging Step 1
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved.
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9.1.2 Two EXO® Full Face Masks
Packaging Step 1
Packaging Step 4
Packaging Step 2
Packaging Step 3
Packaging Step 5
Packaging Step 4
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9.2 Use of Kirby Morgan Original
Replacement Parts
Users of Kirby Morgan life support equipment are
cautioned to always use Kirby Morgan original replacement parts. Parts manufactured by third party
companies can cause accidents.
Look for the Kirby Morgan logo on Kirby Morgan products.
This is your assurance that you are getting genuine Kirby
Morgan replacement parts.
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Table of Equivalents
To convert units appearing in Column 1
(left column) into equivalent values in
Column 2 (center column), multiply by
factor in Column 3. Example: To convert
7 gallons into cubic inches, multiply 7 ×
231 = 1617. To convert units appearing in
Column 2 (center) into equivalent values
of units in Column 1 (left), divide by factor in Column 3. Example: To convert 25
horsepower into Btu per minute, divide
25 by 0.02356 = 1061
To Convert
Into
Atmospheres
Atmospheres
Atmospheres
BTU
BTU per hour
BTU per minute
Celsius (Centigrade)
Centimeters
Cubic Centimeters
Cubic Centimeters
Cubic Feet
Cubic Feet
Cubic Inches
Cubic Inches
Days
Degrees (Angle)
Feet
Feet
Feet of Water
Feet of Water
Feet of Water
Feet per Minute
Feet per Second
Foot-Pounds
Foot-Pounds per Minute
Foot-Pounds per Second
Gallons (U.S. Liquid)
Gallons (U.S. Liquid)
Gallons of Water
Horsepower
Horsepower
Horsepower
Horsepower
Hours
Hours
Inches
Inches of Mercury (Hg)
Inches of Mercury (Hg)
Inches of Mercury (Hg)
Inches of Water
Liters
Liters
Micron
Miles (Statute)
Miles per hour (MPH)
Miles per hour
Ounces (Weight)
Ounces (Liquid)
Pints (Liquid)
Pounds
Pounds
Pounds
PSI (Pounds per Sq. Inch)
PSI (Pounds per Sq. Inch)
PSI (Pounds per Sq. Inch)
Quarts
Square Feet
Temperature (oF - 32)
Tons (U.S.)
Watts
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved.
Into To
Convert
Feet of Water
Inches of Mercury (Hg)
PSI (LBS per Sq. Inch
Foot Pounds
Watts
HorsePower
Fahrenheit
Inches
Gallons (U.S. Liquid)
Liters
Cubic Inches
Gallons (U.S. Liquid)
Cubic Feet
Gallons (U.S. Liquid)
Seconds
Radians
Meters
Miles
Atmospheres
Inches of Mercury (Hg)
PSI (Lbs per Sq. Inch)
Miles per Hour
Miles per Hour
BTU
Horsepower
Horsepower
Cubic Feet
Cubic Inches
Pounds of Water
BTU per Minute
Foot-Pound per Minute
Foot Pounds per Second
Watts
Days
Weeks
Centimeters
Atmospheres
Feet of Water
PSI (Lbs. per Sq. Inch)
PSI (Lbs. per Sq. Inch)
Cubic Centimeters
Gallons (U.S. Liquid)
Inches
Feet
Feet per Minute
Feet per Second
Pounds
Cubic Inches
Quarts (Liquid)
Grains
Grams
Ounces
Atmospheres
Feet of Water
Inches of Mercury (Hg)
Gallons
Square Inches
Temperature (oC)
Pounds
Horsepower
Document #130418001
Multiply By
Divide By
33.9
29.92
14.7
778.3
0.2931
0.02356
o
C x 1.8 + 32
0.3937
0.0002642
0.0001
1728
7.48052
0.0005787
0.004329
86.400
0.01745
0.3048
0.0001894
0.0295
0.8826
0.4335
0.01136
0.6818
0.001286
0.0000303
0.001818
0.1337
231
8.3453
42.44
33,000
550
745.7
0.04167
0.005952
2.54
0.03342
1.133
0.4912
0.03613
1000
0.2642
0.00004
5280
88
1.467
0.0625
1.805
0.5
7000
453.59
16
0.06804
2.307
2.036
0.25
144
0.5555
2000
0.001341
97
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