Kirby 47 User manual

Kirby Morgan 47 Helmet
Operations and Maintenance Manual
KMDSI Part #100-070
Patented, Foreign Patents Pending, other patents apply.
D
IV
BY MORGA
N
c
.
K
IR
In
ES
YSTEMS,
Kirby Morgan Dive Systems, Inc.
1430 Jason Way
Santa Maria, CA 93455, USA
Telephone (805) 928-7772, FAX (805) 928-0342
E-Mail: [email protected], Web Site:www.KirbyMorgan.com
Manual prepared by Marine Marketing and Consulting, Dive Lab, Inc., and KMDSI.
NOTE: This manual is the most current for the Kirby Morgan 47 Helmet. It is page dated May 2007. Future changes
will be shown on page III and the changed pages will carry the date of change. Previous manuals may not reflect these
updates.
WARNING
Diving with compressed breathing gas is a hazardous activity. Even if you do everything
right there is always the danger that you may be killed or injured. No piece of diving
equipment can prevent the possibility that you may be killed or injured any time you
enter the water.
The Kirby Morgan 47 helmet meets or exceeds all performance and testing requirements of all government and non-government testing agencies throughout the world. It is approved for use on all
commercial and military work underwater. Only Kirby Morgan masks and helmets have achieved the
CR (Commercially Rated) mark, the highest United States of America rating.
SuperLite, Band Mask, KMB, KMB BandMask, Kirby Morgan, DSI, Diving Systems International, EXO, SuperFlow, REX,
SuperMask, the color yellow on diving helmets and masks, and DECA are all registered trademarks of Kirby Morgan Dive Systems,
Inc. Use of these terms to describe products that are not manufactured by KMDSI is not permitted.
The two dimensional images (such as photographs and illustrations) of our products are © copyrighted and trademarks of Kirby
Morgan Dive Systems, Inc. The three dimensional forms of our products are trademark/trade dress protected.
© Copyright 1970-2007 Kirby Morgan Dive Systems, Inc. All rights reserved. This manual is made available for the express use of
the owner of this Kirby Morgan product. No part of this manual may be reproduced, stored in any retrieval system, or transmitted,
or used in any form or by any means, whether graphic, electronic, mechanical, photocopy, or otherwise by technology known or
unknown, without the prior written permission of Kirby Morgan Dive Systems, Inc.
Document Number 070604002
Kirby Morgan 47
WARRANTY INFORMATION
Kirby Morgan Dive Systems, Inc. warrants every new mask, helmet, or KMAC Air Control System to be
free from defects in workmanship for a period of ninety (90) days from date of purchase. This warranty
covers all metal, fiberglass, and plastic parts. This warranty does NOT cover rubber parts, communications
components, or headliners. In addition, due to the electrolytic nature of underwater cutting and welding,
chrome plating cannot be warranted when the diver engages in these activities.
Should any part become defective, contact the nearest authorized 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.
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© Copyright 1970-2007 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 070604002
Kirby Morgan 47
RECORD OF CHANGES
It is the responsibility of the owner of this product to register their ownership with Kirby Morgan Dive
Systems, Inc., by sending the warranty card provided. This card is to establish registration for any necessary
warranty work and provides a means of communication that 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
Description of Change
© Copyright 1970-2007 Kirby Morgan Dive Systems, Inc. All rights reserved. Document #070604002
Page Number
III
Kirby Morgan 47
WARNING
Diving with compressed breathing gas is a hazardous activity. Even if you do everything
right there is always the potential for serious injury or death. No one piece of diving
equipment can prevent the possibility that you may be injured or killed any time you
enter the water. We do not herein make any effort to teach the principles of diving. The
information in this manual is intended for users of Kirby Morgan helmets and persons
that maintain or service Kirby Morgan helmets.
IV
© Copyright 1970-2007 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 070604002
Kirby Morgan 47
Contents
Definition of Signal Words Used in this Manual
X
Chapter 1.0 - General Information KMDSI Products
1.1 Introduction
1.2 Full-Face Masks and Manifolds
1.3 Kirby Morgan Diving Helmets
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Chapter 2 - Description & Operational Specifications Kirby Morgan 47
2.1 Product Specifications
2.2 Regulator Performance
2.2.1 REX™ Regulator
2.2.2 Minimum Operating Temperature
2.3 Cage Code
2.4 CR Standards
2.5 Operational Specifications & Limitations
2.6 Helmet Features
2.7 General Description
2.7.1 Helmet Shell
2.7.2 Gas Flow Systems
2.7.3 Emergency Gas Supply System (EGS)
2.7.4 Helmet Attachment to the Diver
2.7.5 Sealing Arrangement
2.7.6 Reducing Carbon Dioxide
2.7.7 Communications
2.7.8 Equalizing the Middle Ear
2.7.9 Face Port or Viewing Lens
2.8 Accessories
2.8.1 Eye Protection for Welding
2.8.2 Helmet Carrying Bag
2.8.3 Special Regulator Tools for REX™ Regulator
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Chapter 3.0 - Operating Instructions
3.1 Introduction
3.2 Design Purpose
3.3 First Use of Your Kirby Morgan Diving Helmet
3.4 Initial Adjustments to Your Helmet
3.4.1 Head Cushion 3.4.2 Trimming the Neck Dam
3.4.3 Adjusting the Neck Pad
3.5 Pre Dress-In Procedure
3.5.1 Pre-Dive Visual Inspection
3.6 Preparing the Helmet for Diving
3.6.1 Clean Face Port
3.6.2 Check Moving Parts
3.6.3 Check Communications
3.6.4 One Way Valve Check
3.7 Emergency Gas System (EGS)
3.8 Setting Up to Dive
3.8.1 Flushing Out the Umbilical the Helmet 3.8.2 Connecting the Umbilical to the Helmet
3.8.3 Opening the Breathing Gas Supply to the Helmet 3.8.4 Fogging Prevention
3.8.5 Donning The Kirby Morgan Helmet
3.8.6 Testing the Breathing System
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© Copyright 1970-2007 Kirby Morgan Dive Systems, Inc. All rights reserved. Document #070604002
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Kirby Morgan 47
3.8.7 Sealing Integrity Check
3.8.8 Adjust Regulator for Low Work Rates
3.9 Removing the Helmet
3.10 Diving Procedures
3.10.1 Standing By to Dive
3.10.2 Attaching the Umbilical to the Harness
3.10.3 Diver Dons Helmet
3.10.4 Diver Check Gas Flow Systems
3.10.5 Communications Check
3.10.6 Diver Ready
3.10.7 Water Entry and Descent
3.11 Emergency Procedures
3.11.1 Flooding
3.11.2 Inhalation Resistance
3.11.3 Gas Flow Stops
3.11.4 Demand Regulator Free Flow
3.12 Post Dive Procedures
3.12.1 Removing the Equipment
3.12.2 Removing the Helmet
3.12.3 Storage of the Helmet Between Dives
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Chapter 4.0 - Troubleshooting
4.1 General
4.2 Communication Malfunction
4.3 One Way Valve Malfunction
4.4 Side Valve Malfunction
4.5 Water Leakage Into Helmet
4.6 Demand Regulator Malfunction
4.7 Emergency Gas Supply Valve
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Chapter 5.0 - Inspection and Maintenance
5.1 Daily Maintenance
5.2 Monthly Maintenance
5.4 Yearly
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Chapter 6.0 - General Preventative Maintenance
6.1 Introduction
6.2 Required tools, Sealing, Cleaning Agents, Lubrication
6.2.1 Component and Parts Cleaning
6.2.2 Component and Parts Lubrication 6.2.3 Teflon Tape
6.2.4 RTV Sealant
6.2.5 Thread Locker
6.3 General Cleaning & Inspection Procedures
6.3.1 O-Ring Removal/Inspection/Cleaning and Lubrication
6.3.2 General Cleaning Guidelines 6.3.2.1 Mild Soap Solution for General Cleaning and Leak Detector Use 6.3.2.2 Acidic Cleaning Solution and Procedures 6.3.2.3 Germicidal Cleaning Solutions and Procedure 6.4 Daily Maintenance 6.5 Monthly Maintenance (or between jobs)
6.5.1 Locking Collar Assembly & Helmet Ring 6.5.2 Neck Dam Ring Assembly 6.5.3 Head Cushion and Chin Cushion 6.5.4 Communications Inspection 63
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© Copyright 1970-2007 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 070604002
Kirby Morgan 47
6.5.5 Lubricate Nose Block O-Rings 71
6.6 REX Demand Regulator & Exhaust System Post Dive Cleaning & Sanitizing 72
6.6.1 Post Dive Disassembly 72
6.6.2 Sanitizing
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6.6.3 Post Dive Reassembly
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Chapter 7.0 - Breathing System Maintenance and Repairs
7.1 Introduction
7.2 Torque Values
7.3 One Way Valve
7.3.1 Disassembly Of The One Way Valve
7.3.2 Reassembly of the One Way Valve
7.4 Side Block Assembly 7.4.1 General
7.4.2 Removal of the Bent Tube
7.4.3 Separating the Side Block Assembly from the Helmet Shell
7.4.4 Side Block Assembly Replacement
7.5 Defogger Valve
7.5.1 Disassembly of the Defogger Valve
7.5.2 Cleaning and Lubricating
7.5.3 Reassembly of the Defogger Valve
7.6 Emergency Valve Assembly
7.6.1 Disassembly of the Emergency Valve
7.6.2 Cleaning and Lubricating
7.6.3 Reassembly of Emergency Valve
7.7 Bent Tube Assembly
7.7.1 General
7.7.2 Removal of the Bent Tube Assembly
7.7.3 Inspection of Bent Tube Assembly
7.7.4 Reinstallation of the Bent Tube Assembly
7.8 Demand Regulator & Exhaust System Overhaul
7.8.1 System Disassembly
7.9 Cleaning REX Regulator Parts
7.9.1 Precautions for Cleaning
7.9.2 Cleaning Instructions
7.10 REX Regulator Re-Assembly
7.11 Testing the REX Demand Regulator for Proper Adjustment
7.11.1 REX Adjustment Troubleshooting
7.12 Oral/Nasal Mask
7.12.1 Oral/Nasal Removal 7.12.2 Inspection of Oral/Nasal
7.12.3 Oral/Nasal Replacement
7.13 Reinstalling the Regulator on the Helmet
7.14 Overpressure Relief / Bleed Valve Overhaul Procedures
7.14.1 Overpressure Relief Valve 7.14.2 Overpressure Relief Valve Disassembly and Cleaning
7.14.3 Overpressure Relief Valve Reassembly
7.14.4 Overpressure Relief Valve Lift Check/Setting
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Chapter 8 - Corrective Maintenance
8.1 General
8.2 Helmet Shell Inspection
8.3 Nose Block Assembly
8.3.1 Nose Block Assembly Removal
8.3.2 Nose Block Device Replacement
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© Copyright 1970-2007 Kirby Morgan Dive Systems, Inc. All rights reserved. Document #070604002
VII
Kirby Morgan 47
8.4 Handle and Weights
8.4.1 Handle Removal 8.4.2 Handle Replacement
8.4.3 Side Weight Removal
8.4.4 Weight Replacement
8.4.5 Top Weight Removal 8.4.6 Top Weight Replacement
8.5 Face Port
8.5.1 General
8.5.2 Face Port, Port Retainer, and Nose Block Device Removal
8.5.3 Face Port, Port Retainer and Nose Block Replacement
8.5.4 Special Note Regarding Ports
8.5.5 Port Retainer
8.6 Neck Dam 8.6.1 Removal of the Neck Dam
8.6.2 Neoprene Neck Dam Replacement 8.6.3 Latex Neck Dam Replacement
8.6.4 Trimming a Latex Neck Seal
8.7 Neck Dam Pull Strap
8.7.1 Neck Dam Pull Strap Removal
8.7.2 Neck Dam Pull Strap Replacement
8.8 Chin Strap
8.8.1 Chin Strap Removal
8.8.2 Chin Strap Replacement
8.9 O-Ring Seal Replacement 8.10 Helmet Ring
8.10.1 Helmet Ring Repairs
8.11 Sealed Pull Pins
8.11.1 Removal of Sealed Pull Pins
8.11.2 Replacement of Sealed Pull Pins
8.12 Swing Tongue Catch 8.12.1 Disassembly of the Swing Tongue Catch
8.12.2 Reassembly of the Swing Tongue Catch
8.13 Locking Collar
8.13.1 Locking Collar Removal
8.13.2 Locking Collar Disassembly
8.13.3 Locking Collar Reassembly
8.14 Head Cushion and Chin Cushion
8.14.1 Head Cushion Foam
8.14.2 Chin Cushion Foam
8.15 Communications System
8.15.1 General
8.15.2 Earphone Inspection
8.15.3 Removal of Communications Assembly
8.15.4 Replacement of Communications Assembly
8.15.5 Microphone Replacement
8.15.6 Earphone Replacement
8.15.7 Waterproof Connector
8.15.7.1 Connector Removal
8.15.7.2 Connector Replacement
8.15.8 Communications Posts 8.15.8.1 Communications Post Removal
8.15.8.2 Communications Post Replacement
VIII
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© Copyright 1970-2007 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 070604002
Chapter 9.0 - Accessories for the Kirby Morgan 47
9.1 Introduction
9.2 Low Pressure Inflator Hose
9.2.1 Installation of the Low Pressure Inflator Hose
9.3 Weld Lens Assembly
9.3.1 Weld Lens Assembly Installation
9.4 Weld Shield Assembly
9.4.1 Weld Shield Assembly Installation
9.5 Use of Quick Disconnect
Table of Equivalents
Appendix 1: Torque Specifications
Note on Torque Specifications
Checklist, Maintenance, and Pre-Dive Inspections
© Copyright 1970-2007 Kirby Morgan Dive Systems, Inc. All rights reserved. Document #070604002
Kirby Morgan 47
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IX
Kirby Morgan 47
Definition of Signal Words Used in this Manual
For your protection, pay particular attention to items identified by signal words in this manual. These terms are identified
as, CAUTION, WARNING AND DANGER. It is especially important for you to read and understand these sections.
DANGER
This word indicates an imminently hazardous situation, which if not avoided, could result in death or serious injury.
WARNING
This word indicates a potentially hazardous situation, which, if not avoided, could result
in death or serious injury.
CAUTION
This word indicates a potentially hazardous situation, which if not avoided, may result in
minor or moderate injury. It may also be used to alert against unsafe practices.
If English is not your native language and you have any 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.
Ceci est important. Veuillez traduire.
WARNING
WARNING
Diese Mitteilung ist wichtig. Bitte übersetzen lassen.
If you have any questions concerning this manual or the operation of your helmet, contact KMDSI (805) 928-7772 or
by Email at [email protected] or Dive Lab Inc. (850) 235-2715 or at [email protected]
IMPORTANT: A word about this manual. We have tried to make this manual as comprehensive and factual
as possible. We reserve the right, however, to make changes at any time, without notice, in prices, colors, materials,
equipment, specifications, models and availability. Since some information may have been updated since the time of
printing, please contact your local KMDSI dealer if you have any questions. To find a dealer near you, please see the
Kirby Morgan web site, www.kirbymorgan.com. Periodically KMDSI Operations and Maintenance Manuals are reviewed. Any updates/changes will be posted on the KMDSI website and may be downloaded for insertion/correction.
Important Safety Information:
This Kirby Morgan diving helmet is intended for use by trained divers who have successfully completed a recognized
training course in surface supplied diving.
X
© Copyright 1970-2007 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 070604002
Kirby Morgan 47
WARNING
Follow all the instructions in this manual carefully and heed all safety precautions. Improper use of this diving helmet could result in serious injury or death.
WARNING
Kirby Morgan Dive Systems, Inc. (KMDSI) warns all divers who use Kirby Morgan diving helmets or masks to be sure to use only KMDSI original parts from a KMDSI authorized dealer. Although other parts, O-rings and fittings may appear to fit your Kirby
Morgan diving helmet or mask, they may not be manufactured to the same standards
maintained by KMDSI. The use of any parts other than KMDSI original parts may lead to
equipment failure and accidents.
WARNING
Diving in waters that are chemically, biologically, or radiologically contaminated is extremely hazardous. Although Kirby Morgan diving helmets may be adapted for use in
some contaminated environments, special training, equipment, and procedures are
necessary. Do not dive in a contaminated environment unless you have been thoroughly
trained and equipped for this type of diving.
Read this manual before using or maintaining the helmet, even if you have experience with other diving helmets. If
you have purchased the helmet new from a dealer, be sure to send in the warranty registration card so we may
keep you informed of any safety notices that affect this product. If you resell or loan this helmet to another diver,
be sure this manual accompanies the helmet and that the person reads and understands the manual. In addition to the
manual a log book should be used to log all repairs, maintenance and use.
WARNING
Diving is a life threatening occupation. Even if you do everything right you can still be
killed or injured. None of the models of Kirby Morgan helmets or masks can prevent accidents, injuries or death due to improper training, poor-health, improper supervision,
improper job requirements, improper maintenance or acts of God.
WARNING
This helmet was completely checked and should be ready to dive as it was shipped
from the factory. However, it is always the diver’s responsibility to check all the components of the helmet prior to diving.
WARNING
Any and all fiberglass repairs done to this helmet MUST be done by a KMDSI factory
trained repair facility. Painting is not recommended by KMDSI. Furthermore, many diving
companies will not allow painted helmets to be used because painting can mask previous fiberglass damage. KMDSI certified technicians are not responsible for certifying
helmets free from damage during annual overhauls.
Helmet shells can be re-gel coated by authorized/certified KMDSI trained technicians
that have received fiberglass training by KMDSI. Helmets that are to be painted for cosmetic purposes, should be first, certified free of fiberglass damage by an authorized
KMDSI technician certified in fiberglass repair. A log entry should be made in the helmet log that the helmet was free of damage prior to painting. Keep in mind other KMDSI
technicians can refuse to work on helmet shells that have previously been painted or
repaired by non KMDSI certified persons.
This manual is supplied to the original purchaser of this helmet. If you have any questions about the use of the helmet
or you need another copy of this manual, contact KMDSI or your nearest KMDSI dealer. It may also be downloaded
free from the KMDSI website at www.KirbyMorgan.com.
© Copyright 1970-2007 Kirby Morgan Dive Systems, Inc. All rights reserved. Document #070604002
XI
Kirby Morgan 47
If you have any questions regarding the use, maintenance, or operation of this helmet, contact KMDSI at (805) 9287772, fax: (805) 928-0342, or e-mail: [email protected]
WARNING
Kirby Morgan masks and helmets are cleaned and lubricated for oxygen service when they come from the factory. However, if the helmet is used with an
oil lubricated air compressor, contamination with hydrocarbons may result.
If the breathing system in the helmet is exposed to hydrocarbons, it must be
cleaned for oxygen service and lubricated with oxygen safe lubricants before
using it again with breathing mixtures containing a high percentage of oxygen. If this is not done, fires and explosions may result, exposing the user to
serious personal injury or death.
Components requiring lubrication, should only be lubricated with oxygen compatible lubricants such as Christo
Lube®, Flourolube®, or Krytox®. Lubricants must be used sparingly and should not be mixed with other lubricants.
WARNING
KMDSI helmets and masks are intended for underwater use only and should only be
used by qualified divers that have received proper training in the use of this type of
equipment. KMDSI helmets and masks should not be used or worn without the appropriate life support systems, such as air or gas supplies and support personnel as described in this manual.
KMDSI helmets and masks should never be used for motor sport racing, aviation /
space craft use, or for chemical warfare use. The helmet must never be used by persons
in poor physical condition, by persons with previous head, neck, or back injuries which
could be aggravated by its use. The helmet should not be used by persons under the influence of drugs or alcohol. Furthermore, infants, children, or persons under the age of
18 should never wear KMDSI helmets and masks. Failure to pay heed to the above could
result in serious injury or death.
WARNING
Never use the helmet without first completing all pre-dive maintenance and set up procedures.
WARNING
Do not use KMDSI masks or helmets in currents exceeding 3.0 knots Use in currents
greater than 3 knots may allow water to enter the exhaust valve, possibly causing regulator flooding.
WARNING
Surface-supplied diving can be a strenuous activity. The Kirby Morgan 47 weighs approximately 30 lbs. KMDSI recommends that persons with a previous neck or back
injury seek professional medical approval prior to engaging in surface supplied diving
operations using the Kirby Morgan 47. Use of the Kirby Morgan 47 with a pre-existing
physical/medical condition may result in death or serious injury.
The information contained in this manual is intended to aid the user in optimizing the performance of this helmet. The
application of some of this information will depend on the diving situation and the use of associated equipment. Many
countries have specific laws and rules regarding commercial diving. It is important for the user to understand the rules,
regulations, and philosophy imposed by the governing, regulating bodies whenever using commercial diving equipment.
XII
© Copyright 1970-2007 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 070604002
Kirby Morgan 47
Whenever KMDSI helmets or masks are used in European Countries, which have adopted the C.E. certification programs, they must only be used with C.E. certified components. Diving operations should only be conducted within the
limits of the operational specifications, and in accordance with the rules and regulations established by the governing
authority in the specific country or geographical location where the diving operations are being conducted. If you have
any questions concerning this manual or the operation of your helmet, contact KMDSI (805) 928-7772 or at [email protected]
KirbyMorgan.com or Dive Lab Inc. (850) 235-2715 or at [email protected]
WARNING
Always read the Material Safety Data Sheet (MSDS) for any chemical - adhesive, cleaning agent, or lubricant - used on your Kirby Morgan helmet. Some of these chemicals
may cause serious bodily injury or death if used improperly or without the proper personal protective equipment.
© Copyright 1970-2007 Kirby Morgan Dive Systems, Inc. All rights reserved. Document #070604002
XIII
Kirby Morgan 47
Handle
Defog free flow valve knob
Port retainer
Helmet shell
Oral nasal mask
Sideblock
EGS valve
Equalization
device
Regulator
adjustment knob
Non-return
valve
Pull pin
Purge button
IAL
LY RATED
B
GE
AR - DIV
EL
A
XIV
-
P
ESSIONAL D
IV
I
TE
RC
F
RO
Rex 3 Exhaust System
NG
The Kirby Morgan 47 helmet
ST E D C O M M
E
Communications
module
™
© Copyright 1970-2007 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 070604002