EXO Full-Face Mask Manual
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.
© ⅯⅯⅩⅥ Kirby Morgan Dive Systems, Inc. All rights reserved.
Document #161012005
65
EXO Full-Face Mask Manual
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.
© ⅯⅯⅩⅥ Kirby Morgan Dive Systems, Inc. All rights reserved.
Document #161012005
EXO Full-Face Mask Manual
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.
© ⅯⅯⅩⅥ 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.
Document #161012005
67
EXO Full-Face Mask Manual
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
Check the seating of the mask seal and lens clamps
on the inside of the mask.
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
© ⅯⅯⅩⅥ Kirby Morgan Dive Systems, Inc. All rights reserved.
Document #161012005
EXO Full-Face Mask Manual
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.
© ⅯⅯⅩⅥ Kirby Morgan Dive Systems, Inc. All rights reserved.
Check the gap on both sides of the lens to be sure it
is equal.
Document #161012005
69
EXO Full-Face Mask Manual
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
70
© ⅯⅯⅩⅥ Kirby Morgan Dive Systems, Inc. All rights reserved.
Document #161012005
EXO Full-Face Mask Manual
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
© ⅯⅯⅩⅥ Kirby Morgan Dive Systems, Inc. All rights reserved.
Document #161012005
71
EXO Full-Face Mask Manual
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.
72
© ⅯⅯⅩⅥ Kirby Morgan Dive Systems, Inc. All rights reserved.
Document #161012005