User manual | Page KIRBY MORGAN DEEP SEA DIVING HELMETS ALL MODELS

KIRBY MORGAN DEEP SEA DIVING HELMETS
ALL MODELS
MONTHLY INSPECTION AND MAINTENANCE CHECKLIST
Appendix A2.2
01-25-17
This inspection is the minimum recommended maintenance and should be performed at least
ONCE A MONTH with Helmet(s) in continuous use (used for more than 20 diving days in a
month) or at least every TWO (2) MONTHS, with Helmet(s) used less than 10 diving days a
month.
This checklist is intended to aid persons performing routine maintenance and inspections of all
KMDSI Helmets. This checklist should be used in conjunction with the applicable Modular
Operations and Maintenance Manual for the model helmet being serviced and is primarily
intended to document the maintenance as it is completed and act as a guide. Specific detailed
procedures for each section of this checklist can be found in the KMDSI Modular Operations and
Maintenance Manuals. This checklist when completed should be retained in the equipment
maintenance files. This checklist is generic in nature and is intended to be used for all models of
KMDSI Diving Helmets.
NOTE: KMDSI strongly recommends that all repairs be performed by persons that have
received official Dive Lab training and are certified as KMDSI certified technicians.
NOTE: Helmets being used in polluted waters, or extreme environments, will require more
frequent inspection and maintenance.
NOTE: This checklist should be used in conjunction with the most current KMDSI Modular
Operations and Maintenance Manual. For latest Manual revisions please check the
KMDSI web page at www.kirbymorgan.com.
NOTE: During removal of components for inspection, O-rings and other consumable items may
be reused, providing they are clean and a visual inspection does not reveal any damage
or deterioration.
Page1
NOTE: Perform the Neck Clamp/Yoke Assembly, Helmet, and Side Block/Demand Regulator
inspection procedures with gas supplies not connected to the Side Block. Attach the gas
supply at Step 5 of the “Side Block/Demand Regulator” inspection procedure.
Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex 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 without
written permission from KMDSI.
© Copyright 1970-2017 Kirby Morgan Dive Systems, Inc. All rights reserved. KMDSI manuals, checklists and technical and training
information is made available for the express use of owner/user of this Kirby Morgan products. No part of this material 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
Copyright 2003-2017, Dive Lab®., Inc. All rights reserved. TechTrnG 03101
1
Date:
Helmet Serial #:
Associated Equipment Serial #(s):
Equipment belonging to: (print name):
PROCEDURES
INITIALS
SL-17A/B NECK CLAMP/YOKE ASSEMBLY
Helmet Attachment Components
NOTE: For SL-17K, SL-17C, SL-27, and KM-37/SS, KM-47, KM57, KM-77, KM-97, skip to step 1, page 3
NOTE: KMDSI recommends that Neck Clamps older than five
years old be removed from service and replaced. However,
neck clamps that show no signs of damage or deterioration
can remain in service if the user/owner elects and should be
inspected at least weekly I.A.W. Steps 1-6 of this procedure.
1. Remove the Neck Clamp/Yoke Assembly from the Helmet.
Perform a visual inspection of all components. Ensure the Neck
Dam has no holes, tears, or damage. The neoprene must be firm.
The Neck Dam should fit snug, but should never fit a diver tight
enough to cause discomfort. Guidance Modular O&M Manual.
Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex 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 without
written permission from KMDSI.
© Copyright 1970-2017 Kirby Morgan Dive Systems, Inc. All rights reserved. KMDSI manuals, checklists and technical and training
information is made available for the express use of owner/user of this Kirby Morgan products. No part of this material 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
Copyright 2003-2017, Dive Lab®., Inc. All rights reserved. TechTrnG 03101
2
Page2
3. Visually inspect the Adjustment Stud on the Neck Clamp for signs
of cracking, distortion, bending, stripped or damaged threads by
loosening Nut (4) all the way to the shoulder of the Stud, and
manually squeezing the Neck Dam Clamp to expose the portion of
the Stud that is normally hidden by the Stud Block. If any damage
is present the, Neck Clamp requires replacement. Guidance
Modular O&M Manual.
2. Visually inspect all metal parts of the Clamp Assembly for damage.
Check the Hinge Pins for loose fit, signs of cracking, distortion or
any damage. Guidance Modular O&M Manual.
4. Check the Rear Hinge Tab and Hinge for signs of cracking,
bending, distortion, or loose fasteners. Guidance, Modular O&M
manual
5. Check the Latch Catch Assembly for proper operation. Check for
worn or damaged parts as well as loose or missing screws. Ensure
the proper Safety Pin is present. Guidance, Modular O&M Manual.
6. Test mate the Neck Clamp/Yoke to the Helmet. Check for
proper Clamp adjustment and smooth operation. When properly
adjusted, use a 7/16” open-end wrench on Nut as a back-up
wrench and a 7/16” deep well socket with a torque wrench.
Ensure Lock Nut is torqued to 60 inch lbs. Repair/replace
and/or adjust parts as necessary. Guidance Modular O&M
Manual.
HELMET MODELS: SL-17K, SL-17C, SL-27,
KM-37/SS, KM-47, KM-57, KM-77, KM-97
HELMET ATTACHMENT COMPONENTS
(Neck Ring Assembly)
1. Remove the Neck Ring Assembly from the Helmet. Remove and
inspect the O-ring for damage or deterioration, nicks or cuts.
Clean and inspect the O-ring groove for damage. Lightly lubricate
with recommended lubricant and reinstall. Guidance, Modular
O&M Manual.
2. Inspect the interior mounted chin strap (current) and/or the strap
mounted on the neck dam ring for signs of wear or damage. Guidance,
applicable Manual.
Page3
Note: If no interior mounted chin strap present, KMDSI strongly
recommends that the helmet be upgraded with the interior
mounted chin strap.
3. Inspect the Neck Dam material for signs of wear or damage.
Ensure the Neck Dam has no holes, tears, or damage. The
neoprene must be firm. The Neck Dam should fit snug, but
should never fit a diver tight enough to cause discomfort. Check
to ensure it is free of deterioration. Guidance, Modular O&M
Manual.
Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex 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 without
written permission from KMDSI.
© Copyright 1970-2017 Kirby Morgan Dive Systems, Inc. All rights reserved. KMDSI manuals, checklists and technical and training
information is made available for the express use of owner/user of this Kirby Morgan products. No part of this material 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
Copyright 2003-2017, Dive Lab®., Inc. All rights reserved. TechTrnG 03101
3
4. Visually inspect the locking collar for signs of damage. Check to
ensure the neck pad can slide to allow for proper adjustment.
Check for loose or missing fasteners. Guidance, Modular O & M
Manual.
5. Check the two sealed Pull Pins for smooth operation. Visually
inspect for signs of oil leakage. Guidance, Modular O & M
Manual.
Caution: If Sealed Pull Pins do not operate smoothly, or if oil is
leaking, from the Pull Pins, the Pull Pins should be serviced by
an Authorized / Certified KMDSI Repair Technician trained to
overhaul Pull Pins.
6. Visually inspect the metal Helmet Ring at the base of the Helmet
for signs of damage to the sealing surface. Any damage requires
an inspection by an Authorized KMDSI Technician. Guidance
Modular O&M Manual.
7. Check the Swing Catch for smooth operation. Check for
obvious worn or damaged parts and components. Guidance
Modular O&M Manual.
Page4
1. Visually inspect Helmet Shell exterior for loose or missing fasteners
and obvious signs of fiberglass damage; including cracks, gouges,
or depressions.
NOTE: Any gouges deeper than 1/16” that show bare fiberglass
should be repaired. Fiberglass and gel coat repairs must be
completed by a technician that has received certification for
Helmet Shell repairs by KMDSI or Dive Lab, Inc.
2. Remove and inspect Head Cushion for tears, broken snaps and/or
neck strap damage. Lightly lubricate male snaps with Molykote®
silicone grease. Check the condition of the foam. Repair/replace as
necessary. Guidance Modula O&M Manual.
HELMET SHELL, ALL MODELS OF KMDSI
DIVING HELMETS
Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex 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 without
written permission from KMDSI.
© Copyright 1970-2017 Kirby Morgan Dive Systems, Inc. All rights reserved. KMDSI manuals, checklists and technical and training
information is made available for the express use of owner/user of this Kirby Morgan products. No part of this material 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
Copyright 2003-2017, Dive Lab®., Inc. All rights reserved. TechTrnG 03101
4
3. Remove the Earphones and Microphones from their holders.
Remove the covers from the Earphones and inspect. Remove
microphone from Oral Nasal Mask. Clean and repair/replace as
necessary. Perform a communications check. Guidance Modular
O & M Manual.
4. Remove the Nose Block Device and Oral Nasal Mask. Remove the
Oral Nasal Valve body as an assembly. Clean the oral nasal valve
and Valve Body as an assembly. Clean the Oral Nasal Mask.
Inspect Mask and Valve Assembly for damage or deterioration.
Replace the Oral Nasal Mask if any damage is found. Replace the
Oral Nasal Valve if it appears dried, stiff, or does not lay flat.
Clean and inspect the Nose Block Pad, Shaft and O-rings for wear.
Replace the Pad if deteriorated or damaged. Replace O-rings if any
signs of wear or damage are present. Lightly lubricate the Shaft Orings and the Shaft, then reinstall. Reinstall Oral Nasal Mask and
Valve Assembly. Guidance Modular O & M Manual.
5. On The SL-17 A/B Remove Helmet O-ring at the base of the
Helmet. Wipe O-ring and O-ring groove with a clean cloth.
Inspect the O-ring groove for damage. Inspect the O-ring for
cracking, cuts, damage or deterioration and replace if necessary.
Lightly lubricate the Neck Dam O-ring and reinstall on the Helmet.
Guidance Modular O & M Manual.
6. Without air to the Helmet, check the operation of the Steady Flow
Valve and Emergency Supply Valve. If the Valves do not operate
smoothly they should be disassembled, cleaned, and lubricated.
Guidance, Modular O&M manual.
7. Remove the Water Dump Valve Cover and inspect the Water
Dump/Dewatering Valve and Seat for damage or contamination.
Ensure the Valve material is not hardened, distorted, or warped.
Replace the Valve if questionable. Reinstall the Cover. Guidance,
Modular O&M manual.
Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex 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 without
written permission from KMDSI.
© Copyright 1970-2017 Kirby Morgan Dive Systems, Inc. All rights reserved. KMDSI manuals, checklists and technical and training
information is made available for the express use of owner/user of this Kirby Morgan products. No part of this material 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
Copyright 2003-2017, Dive Lab®., Inc. All rights reserved. TechTrnG 03101
5
Page5
NOTE: Ensure gas supplies ARE NOT attached to the Helmet EGS
and steady flow valve; remove protective dust caps, DO NOT
open the Steady Flow/Defogging Valve.
SIDE BLOCK/DEMAND REGULATOR
1. Check the Umbilical Supply One-Way Valve for proper operation
by sucking on the Umbilical Adapter with the Emergency Valve
open and the steady flow valve shut. No gas should be drawn
through the One-Way Valve. Guidance Modular O&M manual.
2. Remove the Regulator Cover Clamp, Cover, and Diaphragm.
Visually inspect the interior of the Regulator Body for corrosion or
contamination. Clean as necessary. Guidance Modular O&M
manual.
3. Carefully inspect the Diaphragm for cuts, tears, or deterioration. If
any damage is found, replace the Diaphragm. Guidance Modular
O&M manual.
4. Carefully check the Regulator Exhaust Valve for warping,
distortion, stiffness, or damage. This is checked by pressing on the
Flapper Valve from inside the Regulator. Check the Regulator
Body Valve Seat Spokes. The Spokes should be flat and even.
Straighten if deformed. If the Valve shows signs of damage or
deterioration, replace the Valve. Guidance Modular O&M manual.
5. Attach an air supply source to the Umbilical Adapter and set the
supply pressure to between 135 - 150 psig (9.3 – 10.3 bar). Adjust
the Regulator Adjustment Knob out, until a slight free flow
develops, then adjust in until the free flow just stops and check the
Lever play. There should be between 1/16” - 1/8” of play in the
Lever. Adjust as necessary. Guidance Modular O&M manual.
Reinstall the Diaphragm, the Cover, and the Clamp.
Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex 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 without
written permission from KMDSI.
© Copyright 1970-2017 Kirby Morgan Dive Systems, Inc. All rights reserved. KMDSI manuals, checklists and technical and training
information is made available for the express use of owner/user of this Kirby Morgan products. No part of this material 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
Copyright 2003-2017, Dive Lab®., Inc. All rights reserved. TechTrnG 03101
6
Page6
7. Check the Steady Flow Valve for proper operation.
6. Depress the purge button. On the SuperFlow and SuperFlow 350
regulators the purge button should travel between 1/16”-1/8”
before air flow starts. On the 450 and 455 balanced regulators, the
flexible cover should travel 1/16”-1/8” before air starts to flow.
For the REX the cover should travel between 3/16” and 1/4" before
flow starts. With all regulators depressing the purge more than a
1/4" should result in a strong flow of gas. If the Regulator Purge
travel is less than or greater than amount specified, re-adjust the
Lever. Guidance O&M manual.
NOTE: The Steady Flow Valve will rotate approximately 1 3/4
revolutions from closed to full open. With the air pressure to
the Helmet between 135 - 150 psig (9.3 - 10.3 bar), turning the
Steady Flow Valve ½ turn open should result in a strong flow
of gas through the Defogger Train.
8. Secure the gas supply, then bleed down and remove the umbilical
from the Inlet Adapter.
9. Attach a regulated gas supply (normally the EGS system), adjusted
to between 135 – 150 psig (9.3 – 10.3 bar), to the Emergency
Valve on the Side Block. On the Side Block, open the Emergency
Supply Valve all the way, and then slowly open the regulated gas
supply. Check the function of the Regulator Purge, Regulator
Adjustment Knob, and the Steady Flow Valve in accordance with
previous steps 6 and 7. Check for gas exiting from the One-Way
Valve. There should be no gas exiting the Umbilical Adapter.
NOTE: The Emergency Gas System consists of a good quality First
Stage Regulator equipped with, an Over-Pressure Bleed/Relief
Valve, and an Emergency Gas Supply Hose that connects to the
Emergency Valve on the Helmet Side Block.
Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex 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 without
written permission from KMDSI.
© Copyright 1970-2017 Kirby Morgan Dive Systems, Inc. All rights reserved. KMDSI manuals, checklists and technical and training
information is made available for the express use of owner/user of this Kirby Morgan products. No part of this material 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
Copyright 2003-2017, Dive Lab®., Inc. All rights reserved. TechTrnG 03101
7
Page7
1. Check the hydrostatic date and the last visual inspection record
(“VIP”) of the cylinder. Ensure the date(s) are within the specified
range. The VIP is done at least annually and the hydrostatic test is
done at least every five (5) years.
2. Check the maintenance record of the EGS components to ensure the
First Stage Regulator maintenance has been performed in
accordance with the manufacturer’s recommendations.
3. Check all of the Hoses for signs of blisters, cover slippage, cuts or
abrasions. Replace any Hose(s) that shows signs of
leakage/damage. If a Quick Connect EGS Hose is being used,
inspect the quick connect and fittings for signs of wear/damage.
4. If a Submersible Pressure Gauge is used, ensure it has been
compared to a gauge of known accuracy and inspect the HP hose
for signs of corrosion and damage.
5. Test the First Stage Regulator’s Bleed/Relief Valve. Guidance 6.12
or as per “Appendix 4”: Bleed/Relief Valve Cleaning, Inspection,
and Overhaul Procedures”.
6. Perform a leak check of all EGS components and fittings using
soapy water in a pressurized condition. Repair/replace items as
necessary.
EMERGENCY GAS SUPPLY (EGS)
7. Inspect the Harness Assembly for signs of wear or damage.
Repair/replace as necessary.
Recorded service in helmet maintenance log book
YES_______
NO______
NOTE: KMDSI strongly recommends that only trained certified KMDSI technicians perform
overhauls. The below statement is intended to discourage non trained and non certified persons
from posing as certified KMDSI technicians.
I_____________________________________________hereby certify that I have performed the
work required in the A2.1 and that I am a certified KMDSI / Dive Lab technician.
Print name__________________________Signature__________________________
Date___________________ID#__________Date of Certification________________
I_____________________________________________hereby certify that I have performed the
work required in the A2.1 and I am not a certified KMDSI / Dive Lab technician
Technician / Owner: Print name__________________________________________
KMDSI highly recommends that a certified KMDSI Repair Technician make all repairs and that
only genuine KMDSI repair and replacement parts be used. Owners of KMDSI products that
elect to do their own repairs and inspections should only do so if they possess the knowledge and
experience. All inspections, maintenance, and repairs should be completed using the appropriate
KMDSI Operations and Maintenance Manual(s). Persons performing repairs should retain copies
all replacement component receipts for additional proof of maintenance history. Should any
questions on procedures, components, or repairs arise, please contact Kirby Morgan Dive
Systems, Inc., by telephone at (805) 928-7772 or via e-mail at [email protected], or
contact Dive Lab, Inc., by telephone at (850) 235-2715 or via e-mail at [email protected]
Page8
NOTE: The Kirby Morgan Maintenance and Repair Log Book w/Pen (P/N 125-001)
may be used to record all maintenance performed.
Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex 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 without
written permission from KMDSI.
© Copyright 1970-2017 Kirby Morgan Dive Systems, Inc. All rights reserved. KMDSI manuals, checklists and technical and training
information is made available for the express use of owner/user of this Kirby Morgan products. No part of this material 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
Copyright 2003-2017, Dive Lab®., Inc. All rights reserved. TechTrnG 03101
8

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