KIRBY MORGAN DIVE SYSTEMS

INCORPORATED

KMDSI HELMET & BANDMASK

OPERATOR / USER TRAINING GUIDE
KIRBY MORGAN DIVE SYSTEMS
1430 JASON WAY
SANTA MARIA, CA 93455, USA
TELEPHONE (805) 928-7772
FAX (805) 928-0342
WEB SITE: WWW.KIRBYMORGAN.COM
E-MAIL: [email protected]
October 21, 2009

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 1970-2009 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.
THIS BOOK IS FOR THE USE OF KIRBY MORGAN CUSTOMERS AND USERS OF KIRBY MORGAN DIVING
EQUIPMENT ONLY. IT MAY BE DOWN LOADED FREE OF CHARGE FROM OUR WEB SITES FOR THAT USE ONLY
UNTIL FURTHER NOTICE. IT MAY NOT BE CHANGED OR MODIFIED WITHOUT WRITTEN PERMISSION.

Prepared by Dive Lab, Inc. 1415 Moylan Road, Panama City Beach, FL 32408 USA
Telephone: (850) 235-2715 Web Site: www.divelab.com E-Mail: [email protected]
Document #InspTrnG 03100
1
 TABLE OF CONTENTS

TITLE PAGE 1

TABLE OF CONTENTS 2-3

MAINTENANCE AND TRAINING POLICY CHANGES 4 - 13

ENABLING OBJECTIVES:
SL-17 A/B, 17C, 17K, 27, KM-37, 47, 57, 77 14 - 16

MAINTENANCE LOG 17

MONTHLY INSPECTION AND MAINTENANCE:

SL-17 A/B, 17C, 17K, 27, KM-37, 47, 57, 77 18 - 25

DAILY SET-UP: SL-17 A/B, 17C, 17K, 27, KM-37, 47, 57, 77 26 - 31

SUPERVISORS EQUIPMENT CHECKS PRIOR TO ENTRY:

SL-17 A/B 32 35

SUPERVISORS EQUIPMENT CHECKS PRIOR TO ENTRY:

17C, 17K, 27, KM-37, 47, 57, 77 36 - 38

SUPERVISORS IN-WATER CHECKS:

SL-17 A/B, 17C, 17K, 27, KM-37, 47, 57, 77 39 - 40

DAILY POST DIVE CLEANING, MAINTENANCE, & INSPECTION

SL-17 A/B, 17C, 17K, 27, KM-37, 47, 57, 77 41 - 43

BLEED/RELIEF VALVE: CLEANING INSPECTION AND OVERHAUL

PROCEDURES 44 - 47

QUICK SANITIZING PROCEDURES 48 - 49

KMB 18/28 ENABLING OBJECTIVES 50 - 51

MONTHLY MASK INSPECTION: KMB 18/28 52 - 56

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 2
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
 TABLE OF CONTENTS

DAILY SET-UP: KMB 18/28 57 - 62

SUPERVISORS EQUIPMENT CHECKS PRIOR TO ENTRY: KMB 18/28 63 65

SUPERVISORS IN-WATER CHECKS: KMB 18/28 66 - 68

POST DIVE CLEANING, MAINTENANCE, AND INSPECTION:

KMB 18/28 69 71

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 3
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
 KIRBY MORGAN DIVE SYSTEMS, INC.
MAINTENANCE AND TRAINING POLICY CHANGES
4-14-09

Kirby Morgan Dive Systems, Inc., ( KMDSI ) and Dive Lab, Inc., constantly
works on changes that will aid KMDSI dealers, diving contractors, and individual users
of KMDSI equipment the ability to track helmet and band mask maintenance and/or
repair.
KMDSI regularly revises all the SuperLite Helmet Operations and Maintenance
Manuals and continuously works to improve all KMDSI equipment manuals. The current
checklists are also available on the KMDSI website www.kirbymorgan.com, as a
download. It is intended that users of KMDSI helmets and masks use these checklists
when performing maintenance and/or using the equipment. These checklists are
considered the minimum equipment guidelines. These checklists should be tailored by
the user to meet the user requirements based on use and environmental conditions.

Diving Contractor Maintenance Policies:

Most diving contractors are requiring that their divers have their helmets and
masks inspected by an authorized KMDSI trained technician, and some even require that
only a KMDSI Certified Technician conduct repairs. KMDSI cannot override the
maintenance and repair policies set by companies or organizations, but does strongly
recommend companies carefully evaluate their policies and incorporate the KMDSI
maintenance and repair recommendations to minimize unnecessary and redundant
procedures. The KMDSI maintenance checklists represent the minimum recommended
maintenance.

All KMDSI Helmets and Masks are designed with the professional diver in mind.
Most maintenance and repairs can be performed by the owner/user using common hand
and test tools following the procedures in the appropriate KMDSI Operations and
Maintenance Manual. The owner can purchase genuine Kirby Morgan parts and
components from any Authorized KMDSI Dealer. KMDSI strongly recommends that
person(s) electing to do their own maintenance and repairs, to do so only if they have the
proper tools and background training and experience to perform the maintenance.
Maintenance and repair training, is available by Dive Lab Inc., as well as other specially
authorized KMDSI Dealers. The A2.1 Overhaul, Maintenance, and Inspection Checklist
should be performed at least annually and as dictated by condition revealed during
daily/monthly inspection. The A2.2 Monthly Inspection, and Maintenance Checklist
should be performed at least once a month, and/or as stated in the procedure. The A2.3
Daily Set-up and Functional Checklist should be completed prior to commencement of
diving operations. All persons performing repairs should keep good maintenance records
and all receipts. Technical questions can be addressed to KMDSI or Dive Lab or any
Authorized KMDSI Dealer.

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 4
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
 KIRBY MORGAN DIVE SYSTEMS, INC.
MAINTENANCE AND TRAINING POLICY CHANGES
4-14-09

Appendices:
All Helmet and Band Mask Checklists are similar. The checklists are kept
separate from the operations and maintenance manuals to minimize time required for
changes due to procedural or equipment changes.
Appendix 2: KMDSI Recommended Maintenance and Checklists for all
SuperLite and KM Helmet models
A2.1 Overhaul, Inspection and Maintenance
A2.2 Monthly Helmet Inspection
A2.3 Daily Helmet and EGS Set-up and Functional Checklist
A2.4 Supervisors Equipment Checks (prior to water entry)
A2.5 Supervisors (in-water checks)
A2.6 Post Dive Cleaning Maintenance and Inspection

Appendix 3: KMDSI Maintenance Log

Appendix 4: Bleed/Relief Valve
Appendix 5: Quick Sanitizing Procedures
Appendix 6: Thread Insert Testing Procedure

MAINTENANCE AND INSPECTION PROCEDURES / POLICIES:

The following section describes details and specific maintenance and inspection
procedures that are used to complete the daily, monthly, and annual checklists, to ensure
optimum reliability and performance. These procedures are used in conjunction with the
daily pre and post dive maintenance checklists. The periodicities called out in the
appendix section of each checklist are the minimum recommended for Helmets for Bank
Masks being used under good conditions. Equipment used in harsh conditions, i.e.,
contaminated water, welding / burning operations, or jetting, will require more frequent
servicing.

The intention of the maintenance checklists is to help maintain all Helmet and
Mask components in good working order in accordance with KMDSI factory
specifications and to identify worn or damaged parts and components before they affect
safety, performance, and reliability. Whenever the serviceability of a component or part
is in question, or doubt exists, replace it. All components and parts have a service life
and will eventually require replacement.
NOTE: The side block (43a or 43b) does not need to be removed from the
helmet annually providing, after removal, helmet components do not show excessive

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 5
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
 KIRBY MORGAN DIVE SYSTEMS, INC.
MAINTENANCE AND TRAINING POLICY CHANGES
4-14-09

corrosion and verdigris. KMDSI recommends that at a minimum, the side block be
completely removed at least every three (3) years. Clean and inspect the stud and
securing screw and replace it if bent, striped, or any damage is detected.

NOTE: The pipe thread fittings used on the umbilical adapter (67) and the
emergency gas valve (50) are the only fittings that require sealing with Teflon tape.
Liquid Sealant is not recommended for pipe threads. When installing Teflon tape on
pipe threads, 3 mil tape should be used. Apply the tape starting one thread back from the
end of the fitting in a clockwise direction under tension. 1- 1/2 wraps is all that is
needed. The use of more than 1-1/2 wraps could cause excess Teflon tape to travel into
the breathing system.
In all, Helmet and Band Mask Manuals, chapters 5, 6, 7, and 8 gives guidance on
all routine and corrective maintenance and repairs. Disassembly and reassembly of
components is explained in a step-by-step manner that may not necessarily call out that
all O-rings and normal consumable items will be replaced. The manual is written in this
way so that if an assembly, component, or part is being inspected or disturbed between
normal overhaul intervals it is acceptable to reuse O-rings and components providing
they pass a visual inspection (Section 5.3.1.). When conducting scheduled overhauls all
O-rings should be replaced. The side block should be removed from the helmet at least
every three (3) years so that the stud and securing screw can be inspected. All O-rings
should be lubricated with the appropriate lubricant.

Lubrication / Cleanliness:

All new Helmets and Band Masks are lubricated during assembly at KMDSI
using Christo Lube. Seasoned Helmets and Band Masks that have previously been
used for air diving but are also intended to be used with breathing gas mixtures in excess
of 50% oxygen by volume, should be cleaned in accordance with the applicable
Operations and Maintenance Manual and lubricated with oxygen compatible lubricants
such as Christo-Lube, Flourolube, Krytox, Tribolube or other oxygen compatible
lubricants. DO NOT MIX LUBRICANTS! All breathing air supply systems must be
filtered and must meet the requirements of grade D quality air or better. Helmets and
band masks used for air diving or enriched air at 50 % oxygen or less can be lubricated
with food grade silicone grease Dow Corning 111 or equivalent. KMDSI uses Christo-
Lube at the factory for lubrication of all gas train components requiring lubrication, and
highly recommends its use.

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 6
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
 KIRBY MORGAN DIVE SYSTEMS, INC.
MAINTENANCE AND TRAINING POLICY CHANGES
4-14-09

Before 1999, Kirby Morgan Dive Systems, Inc., used Danger and Warning
Notices in the helmet and mask owner s manual limiting the breathing gas percentage to
less than 23.5 percent oxygen. This was due primarily to cleaning issues in regards to
possible fire hazards and was in compliance with the recommendations of the Association
of Standard Test Methods (ASTM), National Fire Protection Agency (NFPA), and the
Compressed Gas Association (CGA) as well as other industry standards. During the
1990 s open circuit scuba use of enriched-air (Nitrox) by technical and recreational divers
became very popular, and as use increased, so did the number of combustion incidents
during the mixing and handling of the breathing mixtures. These combustion incidents
brought attention to the dangers and inherent risks associated with oxygen and oxygen
enriched gas mixtures.
KMDSI cannot dictate or override regulations or recommendations set forth by
industry standards or governing bodies pertaining to enriched gas use. However, it is the
opinion of KMDSI and Dive Lab that breathing gas mixtures up to 50% oxygen by
volume should not pose a significant increased risk of fire or combustion in Kirby
Morgan Helmets and Masks low-pressure components and does not warrant the need for
the stringent specialized oxygen cleaning and post-sampling particulate analysis normally
accomplished for components used in high pressure oxygen valves, regulators, and piping
systems. The decision for using 50% has been primarily based on a long history of
operational field use of KMDSI helmets and masks, by the US Navy and Commercial
Diving Industry. However, this is not intended to down play the need for cleaning and
maintenance. All helmets and masks, as well as gas transporting components should be
maintained carefully and cleaned at regular intervals and/or whenever contamination is
found or suspected.
KMDSI feels confident that as long as Kirby Morgan helmets and masks are cleaned and
maintained in accordance with the procedures set forth in the applicable maintenance manuals
and maintenance checklist procedures, the equipment should not pose a significant increased risk
of a fire or ignition originating in the helmet or mask low-pressure<250 psig (<17.2 bar) or less
components when used with enriched gases of up to 50% oxygen. However, CAUTION should
be exercised any time enriched gases are handled or used. In general, helmets and masks used
primarily for mixed gas use are subject to far less oil and particulate contamination than those
used for air diving. For this reason, helmets and masks commonly used with both air and
enriched breathing gases should be cleaned and maintained with even greater care and vigilance.
It is important that all internal gas-transporting components, i.e., side block, bent tube, and
demand regulator assemblies remain clean and free of hydrocarbons, dirt, and particulates.
Whenever the equipment is depressurized, all exposed ports or fittings should be plugged /capped
to help maintain foreign material exclusion. Gas train components should be cleaned according

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 7
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
 KIRBY MORGAN DIVE SYSTEMS, INC.
MAINTENANCE AND TRAINING POLICY CHANGES
4-14-09

to the procedures outlined in the applicable Operations and Maintenance Manual at least
annually and whenever contamination is suspected or found. Normal interior and
exterior surfaces should be cleaned at least daily at the completion of daily diving
operations.
Helmets and masks used in waters contaminated with oils and other petroleum or
chemical contaminates will require cleaning after each dive.

Helmet and mask components requiring lubrication should be lubricated sparingly

with lubricants approved for oxygen use such as Christo-Lube, Krytox, or
Flourolube. KMDSI highly recommends using Christo-Lube, and uses Christo-
Lube during the assembly of all KMDSI gas train components.
Regardless of the approved lubricant used, avoid mixing different kinds of
lubricants. Persons mixing, handling, and working with breathing gases should be
properly trained in all aspects of gas safety handling and use.
CAUTION: Do not use lubricants of any kind on the diaphragm or exhaust
valves. Use of lubricants on exhaust valves can attract and hold debris that could
interfere with the component.

NOTE: Refer to Chapters 6, 7, and 8 for removal and disassembly / reassembly

procedures.

NOTE: The helmet weights do not need to be removed from the helmet unless
fiberglass damage is present or suspected.
NOTE: During annual or routine overhauls, all O-rings and soft goods including
exhaust valves should be replaced. KMDSI offers standard overhaul kits that have all the
necessary parts.
NOTE: The neck dam rubber need not be replaced as long as inspection reveals
no damage, or significant wear and the rubber components are not dried out.
NOTE: The oral nasal mask requires replacement only if inspection reveals
damage, distortion, or signs of damage. The oral nasal flapper valve should be replaced at
least annually.
NOTE: All threaded fasteners and parts require careful cleaning and inspection
as well as the mating parts. Replace any and all threaded parts or components that show
signs of wear or damage.

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 8
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
 KIRBY MORGAN DIVE SYSTEMS, INC.
MAINTENANCE AND TRAINING POLICY CHANGES
4-14-09

KIRBY MORGAN HELMETS AND BAND MASK CHECKLISTS/TRAINING:

Kirby Morgan Dive Systems, Inc., ( KMDSI ) has developed the pre and post
dive maintenance checklists as well as the other maintenance checklists to assist divers,
tenders, and diving supervisors. The new checklists are for all KMDSI SuperLite
Helmets, KM-37, 47, 57, 77 and Band Masks and intended to be used as a guide to help
ensure helmets and masks are set-up and maintained properly. In addition, KMDSI is in
the process of standardizing all SuperLite helmet and band mask manuals for those who
use multiple models of KMDSI equipment. KMDSI always welcomes all constructive
criticism on the new checklists, manuals, and products.

Training Policies and Guidelines:

Dive Lab, Inc. oversees all (KMDSI) factory repair and maintenance training for
all Kirby Morgan products. Kirby Morgan authorizes selected overseas dealers,
depending on experience, knowledge, facility assets, and geographical location to teach
KMDSI helmet and band mask technician training. Selected dealers receive additional
training to allow them to teach specific equipment only. All KMDSI training certificates
are issued by Dive Lab upon review of course completion documentation and verification
of the technician trainer certification status. Only Dive Lab can conduct KMDSI dealer
technician training. All KMDSI technicians are issued a technician certification number
which is entered into the technician/operator/user data bank so that KMDSI product and
part changes, as well as bulletins, repair notices, tech tips and updates can be e-mailed.
All non-dealer technicians, as well as persons trained as Operator/User are also on the
mailing list.

The KMDSI training policies and guidelines are intended to help persons
performing repairs, maintenance and training that have received KMDSI standardized
training on the equipment as the manufacture intended. The training also teaches the
parameter of intended use and limitations of the equipment. Non KMDSI dealer
technicians trained by authorized KMDSI dealers are encouraged to teach the KMDSI
operator/user course, however, the course curriculum must be presented within the
guidelines set-up in the basic repair technicians guide, Doc. # TechTmg 03101.

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 9
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
 KIRBY MORGAN DIVE SYSTEMS, INC.
MAINTENANCE AND TRAINING POLICY CHANGES
4-14-09

Only KMDSI dealer technicians are authorized to perform repairs for profit.
Non-dealer technicians must limit repairs to their own equipment, company owned
equipment, and equipment belonging to company employees as dictated by company
policy. Non-dealer technicians performing repairs for profit do so without authorization
of KMDSI or Dive Lab.
It is strongly recommended that all technicians document all repairs and
maintenance. KMDSI dealer technicians must document all work performed on all
KMDSI helmets, band masks, and KMDSI equipment worked on, and records must be
kept. All helmets and band masks must be accompanied by a log book. The log book is
important because it shows the history of use, repair, and maintenance. Dealers receiving
helmets or masks for repair or maintenance must have a log book so they can document
the work they perform. Dealers working on helmets or masks not accompanied by a log
or record of use and maintenance will require at a minimum an inspection IAW appendix
A2.1. The A2.1 must be performed at least once every 12 months on helmets and masks
in use. Helmets and masks that have been in storage for up to 2 years, which have not
been used since the last A2.1 was performed will require a monthly inspection IAW the
A2.2.
Fiberglass and Gel Coat:
KMDSI Dealers should not work on helmets or masks that have had fiberglass
repairs done by someone other than KMDSI certified repair technicians that are certified
to perform fiberglass repairs. Helmets that have been coated with coatings like Rhino
Lining or truck bed urethane should be turned away. Painting of helmets is not
recommended and should be discouraged. Dealers can deny servicing helmets that have
been painted, or show signs of repairs completed by non KMDSI trained technicians, or
repairs made improperly.
All KMDSI certified technician trainers must certify or assist in certifying at least
one technician course per year in order to remain as an active technician trainer. Dealer
technicians are issued a new certificate each year for four years providing they remain
active and abide by all the KMDSI technician guidelines and requirements. Dealers are
required to keep records of repairs and training conducted.

Dealer qualifications are listed on the KMDSI and Dive Lab s website so that
users of KMDSI products can review certification and qualification status. Non-Kirby
Morgan dealers and persons not trained by Dive Lab that perform repairs for profit, do so
against the recommendation of KMDSI and Dive Lab. Non-KMDSI certified persons
that pose as certified KMDSI / Dive Lab trained technicians are a serious safety threat to
the diving industry and all users of KMDSI equipment. Dive Lab trained technicians

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 10
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
 KIRBY MORGAN DIVE SYSTEMS, INC.
MAINTENANCE AND TRAINING POLICY CHANGES
4-14-09
working for diving contractors or as free-lance divers cannot perform repairs for profit,
and can only work on their own equipment, company equipment, and equipment
belonging to the employees of the company, as dictated by company policy. This is done
to prevent persons from trying to become back yard helmet mechanics. All work and
repairs must be documented. Any helmets and masks presented for work that do not have
a log book showing work history, must be overhauled IAW Appendix A2.1.

The KMDSI training and certification policies have been established to help
protect the user, technician, and KMDSI dealers by promoting safety through knowledge,
experience, and the proper maintenance of KMDSI products.

KMDSI dealers that have been trained and authorized to teach technician courses
must teach the course set-up by Dive Lab. Dealers are not allowed to create their own
course curriculum and must teach IAW the training guide and instruction provided by
KMDSI and Dive Lab.

KMDSI technicians can only teach the equipment they were actually trained on as
listed on their certification. All the equipment trained on during technician or operator /
user training (Formally Inspector Training) must be listed on a properly filled out course
completion form sent to Dive Lab no later than 30 days after completion of training with
the $25.00 processing fee.

Dealer technicians that are authorized to teach helmet and band mask technician
training must run at least one technician course per year in order to remain on the active
instructor list.

Dealer Training:
Dealer training is valid for 4 years. Dealer technician certification is renewable
annually by Dive Lab, as directed by KMDSI providing dealers remain eligible.

Dealer Repairs:
Kirby Morgan Dealers that have not received technician training by Dive Lab
may not perform repairs or service on KMDSI equipment until training has been
completed. Dealers may only perform repairs on the KMDSI equipment for which they
have been trained on. Persons working as technicians at a KMDSI dealership that have
not received training by Dive Lab, must only work under the supervision of a trained
KMDSI dealer technician, and that technician is responsible for signing off all work
completed.

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 11
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
 KIRBY MORGAN DIVE SYSTEMS, INC.
MAINTENANCE AND TRAINING POLICY CHANGES
4-14-09

Fiberglass Repair:

Face port insert repair, fiberglass, and gel-coat repairs can only be completed by Dive
Lab trained and certified technicians that have received fiberglass repair training.
Dealers are not allowed to contract out fiberglass, gel-coat or insert repairs made by boat
yards or other non Dive Lab/KMDSI trained persons.

All fiberglass and gel-coat repairs should be documented with before and after
pictures of work. The pictures will be available to the customer as well as KMDSI and
Dive Lab.

All equipment repairs by KMDSI dealers must be documented. The dealer must
provide customer with a cost estimate prior to start of any work or repairs. All work and
repairs are to be clearly documented.

All KMDSI Helmet and Band Mask Technicians that have taken the KMDSI
Repair Technicians Course may teach the KMDSI Operator/User Course IAW the
guidelines laid out in the Repair Technician Training Guide # TechTmg 03101.

KMDSI Helmet and Band Mask Operator/User Course (5-7 hours):

The KMDSI Helmet and Band Mask Operator/User Course is intended to instruct
personnel in the manufacturer s recommended maintenance and set-up procedures, as
well as basic inspection and adjustment procedures. The operator course is not intended
to be a repair technician course and does not qualify person(s) to perform repairs or
overhauls. The course is intended to teach divers, tenders, and diving supervisors how to
make pre-dive assessments as to the condition and serviceability of KMDSI helmets and
band masks based on pre-dive visual inspection and functional tests using the applicable
KMDSI checklists and Operations and Maintenance Manuals. The course usually takes
5-8 hours. The course certificate is valid for two years initially and three years upon re-
certification.

KMDSI Maintenance and RepairTechnician Course (3 day):

The KMDSI Technician Course is intended to instruct technicians and users of
KMDSI helmets and band masks how to perform routine and corrective maintenance
procedures and equipment overhauls. The course covers demand regulator and side
block overhauls, as well as all recommended owner level repairs, including face port
insert testing. The course does not include insert repair or fiberglass and gel coat repair.
The course certificate is valid for three years.

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 12
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
 KIRBY MORGAN DIVE SYSTEMS, INC.
MAINTENANCE AND TRAINING POLICY CHANGES
4-14-09

Certification:
Certificates and wallet cards are only issued by Dive Lab, Inc., upon review of
course completion paperwork. Any Technician or Operators Courses taught by Dealer
Technician must have each attendee complete a course completion form. The Technician
teaching the course should fill out the top portion of the form. All information should be
filled out so that future important notices or changes to procedures can be e-mailed. The
forms should be sent by the Instructor to Dive Lab, Inc., within 30 days of course
completion along with $25.00 (for each certificate to be issued). KMDSI / Dive Lab has
the right to deny certification to any individuals due to previous unethical or practices not
in line with the intent of KMDSI Technician/Operator Courses.

Responsibility of Trained Personnel:

All persons that have received Kirby Morgan training have a responsibility to
ensure the helmets and masks they work on are set-up, and adjusted in accordance with
the applicable pre-dive checklists and the Operations and Maintenance Manuals.
Helmets or masks that fail inspections or tests, as well as those with worn, damaged, or
non-approved components that could affect safety or performance, must be repaired prior
to use. All scheduled maintenance, as well as daily pre and post dive maintenance,
should be documented. Helmets or masks requiring fiberglass or insert repairs, or other
repairs outside the scope of basic technician, must be only be repaired by a certified
KMDSI repair technician trained and authorized to perform the repairs. Many of the
checklists undergo changes from time to time. All Technicians and Operator/Users
should periodically check the Dive Lab and KMDSI web page for manual changes and
updates. New e-mail addresses should be sent to Dive Lab so files can be updated to
ensure important notices and changes can be forwarded. For further information on
training contact Dive Lab at [email protected]

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 13
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
 KIRBY MORGAN OPERATOR / USERS TRAINING
ALL MODELS
17A/B, 17-C, 17-K, 27, AND KM-37, KM-47, KM-57, KM-77
ENABLING OBJECTIVES
(Formerly known as Inspector Training)
10-21-09

Upon completion of the KMDSI Operator / User Course, the trainee will be able to
perform the KMDSI recommended pre-dive inspection and maintenance procedures in
accordance with the KMDSI Inspection and Maintenance Checklists:

A2.2 Monthly Maintenance

A2.3 Daily Set-Up and Functional Checklist
A2.4 Supervisor s Equipment Checks Prior to Entry
A2.5 Supervisor s Equipment Checks In-Water
A2.6 Post Dive Cleaning

State the KMDSI recommended maintenance periodicities and the definitions or

guidelines for each.

NECK DAM/RING ASSEMBLY

Upon instruction of this section the student will be able to:

a) Describe/perform a proper inspection of Yoke/Neck Clamp Assemblies on the
SL-17 A/B Helmet
b) Describe/perform a thorough inspection of the weldment areas of concern.
c) Explain and demonstrate the proper adjustment of the Neck Clamp and Latch
Catch Mechanisms.
d) The areas of inspection and the difference between the Push-Pin Plunger and
the new style Pull-Pin Plunger and the reasons for the upgrade.
e) Demonstrate proper removal, inspection, cleaning, and lubrication of
Helmet/Neck Ring O- ring and state the recommended lubricants.
f) Explain the SL-27, KM-37, 47, 57, 77 type Neck Dam with pull pins. How is
it different than the SL-17A/B.
g) Explain/demonstrate the proper placement of the Safety Pin and Lanyard and
the reasons for it (17A/B only).
h) Describe/perform a thorough inspection of a Neck Dam, both neoprene and
latex. Explain what type of contaminates and environmental conditions will
cause deterioration of each.

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 14
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
HELMET ASSEMBLY

Upon instruction of this section the student will be able to explain:

a) How the KMDSI maintenance and inspection procedures and instructions are
to be used.
b) How the KMDSI maintenance system is structured and where information may
be found.
c) Explain the responsibilities of a KMDSI Technician and Operator / User.
d) Explain/demonstrate a proper, thorough exterior Helmet Inspection and
explain the types of damage that might be found, and areas of concern.
e) Explain and demonstrate the inspection of the Face Port and related
components.
f) Describe/perform a thorough inspection of the Helmet Locking Collar
assembly (SL-17K, 27, KM-37, 47, 57, 77).
g) Describe/perform an inspection of the sealed Pull-Pins and state what they are
looking for and how to identify a Rebuilt Pin from a New Pin (17K, 27, KM-
37, 47, 57, 77) and how the Pins should be serviced.
h) Explain/demonstrate a thorough inspection of the Swing Catch Assembly and
the Helmet Ring, describing areas of concern (17K, 27, KM-37, 47, 57, 77).
i) State the purpose of the Helmet Liner/Cushion and why it should be
maintained in good condition, how it can be tailored to fit.
j) Describe/perform proper inspection and required maintenance of
Communications System.
k) Explain the proper maintenance and inspection of the Oral/Nasal Mask and
Valve Assembly.
l) Explain the purpose of the Oral/Nasal Mask Valve Assembly.
m) State the advantages/disadvantages and limitations of the Double Exhaust and
the reasons.
n) Perform Main Exhaust /Water Dump Valve Inspection, thoroughly describing,
seating surface .

SIDE BLOCK

Upon instruction of this section, the student will be able to explain the inspection and
operation of the following Side Block Components:
a. One-way Valve
b. Defogger Valve
c. Auxiliary Gas or (EGS) Valve
d. Valve Knob Components.

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 15
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
DEMAND REGULATOR

Upon instruction of this section, the student will be able to state and demonstrate:
a) KMDSI recommended daily and monthly maintenance.
b) Properly, clean and inspect using the daily post dive Checklist,
reassemble, adjust, fine- tune the Demand Regulator.
c) Explain sanitizing procedures of the Demand Regulator and associated
components, and what safety precautions must be observed.
d) Explain how Helmet parts and components are cleaned and corrosion is
removed.
e) Explain how to perform O-ring inspections and how to lubricate components.

EMERGENCY GAS SUPPLY

Upon instruction of this section, the student will be able to:

a) State the periodicity for the Hydrostatic and Visual Inspection for the
Emergency Gas Cylinder.
b) Conduct a thorough visual and functional test and inspection of all EGS
components, including the maintenance records to ensure maintenance is in
compliance with manufacturers recommendations.
c) Demonstrate/perform testing of the First Stage Relief Valve.
d) Check/demonstrate/perform the correct recommended setting of the over-
bottom of the First Stage Regulator for the Emergency Gas Supply (EGS)
Cylinder.
e) Explain the hazards involved in not having EGS gas up to the First Stage when
diving.

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 16
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
 KMDSI MAINTENANCE LOG
Appendix 3 (4-14-09)
Helmet or Mask Model# Helmet or Mask Model#
Serial # Serial #
Harness# Harness#
Daily Pre-Dive A2.3 Daily Pre-Dive A2.3
Daily Post Dive A2.6 Daily Post Dive A2.6
Monthly Inspection/Maintenance A2.2 Monthly Inspection/Maintenance A2.2
Overhaul/Inspection A2.1 Overhaul/Inspection A2.1
Other Other
Date Date
Technician (Print) Technician (Print)
Technician (Sign) Technician (Sign)
Remarks Remarks

Check all that apply Check all that apply

Helmet or Mask Model# Helmet or Mask Model#
Serial # Serial #
Harness# Harness#
Daily Pre-Dive A2.3 Daily Pre-Dive A2.3
Daily Post Dive A2.6 Daily Post Dive A2.6
Monthly Inspection/Maintenance A2.2 Monthly Inspection/Maintenance A2.2
Overhaul/Inspection A2.1 Overhaul/Inspection A2.1
Other Other
Date Date
Technician (Print) Technician (Print)
Technician (Sign) Technician (Sign)
Remarks Remarks

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 17
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
 KIRBY MORGAN SUPERLITE DEEP SEA DIVING HELMET
MODELS 17A/B, 17C, 17K, 27, and KM-37, KM-47, KM-57, KM-77
MONTHLY INSPECTION AND MAINTENANCE CHECKLIST
Appendix A2.2
4-14-09

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
Operations and Maintenance Manual for the model helmet being serviced and is
primarily intended to guide and document the maintenance as it is completed. Specific
detailed procedures for each section of this checklist can be found in the Operations and
Maintenance Manuals. This checklist when completed should be retained in the
equipment maintenance files. This checklist is intended to be used for all models of
KMDSI SuperLite and KM-37 Helmets.

NOTE: KMDSI strongly recommends that all repairs be performed by trained

Personnel.

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 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.
NOTE: Perform the Yoke/Neck Clamp 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 18
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
Date:

Helmet Serial #:

Associated Equipment Serial #(s):

Technician (print name):

PROCEDURES INITIALS

SL-17A/B YOKE / NECK CLAMP ASSEMBLY

HELMET ATTACHMENT COMPONENTS
Note: FOR SL-17K, SL-17C, SL-27, AND KM-37, KM-47, KM-57,
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 and 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 Yoke/Neck Clamp Assembly from the Helmet.
Perform a visual inspection of all components. Ensure the Neck
Dam has no holes, tears, and/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 SL-17A/B 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,
and/or any damage. Guidance SL-17A/B O&M Manual.
3. Visually inspect the Adjustment Stud on the Neck Clamp for signs
of cracking, distortion, bending, stripped and/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 SL-
17A/B O&M Manual.

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 19
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
4. Check the Rear Hinge Tab and Hinge for signs of cracking,
bending, distortion, and/or loose fasteners. Guidance, 7.9.4 SL-
17A/B O&M manual
5. Check the Latch Catch Assembly for proper operation. Check for
worn and/or damaged parts as well as loose and/or missing screws.
Ensure the proper Safety Pin is present. Guidance SL-17 A/B
O&M Manual.
6. Test mate the Yoke/Neck Clamp 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 17A/B O&M
Manual.

PROCEDURES

HELMET MODELS: SL-17K, SL-17C, SL-27,

KM-37, KM-47, KM-57, KM-77
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 and / or cuts.
Clean and inspect the O-ring groove for damage. Lightly lubricate
with recommended lubricant and reinstall. Guidance, applicable
O&M Manual.

2. Inspect the Chin Strap of the head liner and/or new style chin strap
attached inside helmet attachment components for signs of wear or
damage. Guidance, applicable O&M Manual.
Note: KMDSI recommends at least one style of the chin strap be
used. Either the strap on the headliner or the chin strap that attaches
inside the helmets.
3. Inspect the Neck Dam material for signs of wear or damage.
Ensure the Neck Dam has no holes, tears, and/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, applicable O&M
Manual.

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 20
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
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, applicable O&M
Manual.

5. Check the two sealed Pull Pins for smooth operation. Visually
inspect for signs of oil leakage. Guidance, applicable 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
Applicable O&M Manual.

7. Check the Swing Tongue Catch for smooth operation. Check for
obvious worn or damaged parts and components. Guidance O&M
Manual.

PROCEDURES
HELMET SHELL, All MODELS OF KMDSI SUPERLITE AND
KM HELMETS
1. Visually inspect Helmet Shell exterior for loose and/or missing
fasteners and obvious signs of fiberglass damage; including cracks,
gouges, and/or depressions.
NOTE: Any gouges deeper than 1/16 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 Helmet Liner/Cushion for tears, broken snaps
and/or neck strap damage. Check the condition of the foam.
Repair/replace as necessary. Guidance O&M Manual.

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 21
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
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 O & M
Manual.

4. Remove the Nose Clearing 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 and/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 Clearing Pad, Shaft
and O-rings for wear. Replace the Pad if deteriorated and/or
damaged. Replace O-rings if any signs of wear or damage is
present. Lightly lubricate the Shaft O-rings and the Shaft, then
reinstall. Reinstall Oral Nasal Mask and Valve Assembly.
Guidance 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, and/or signs of damage/deterioration and replace if
necessary. Lightly lubricate the Neck Dam O-ring and reinstall on
the Helmet. Guidance 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, applicable O&M manual.

7. Remove the Main Exhaust Valve Cover and inspect the Main
Exhaust/Dewatering Valve and Seat for damage and/or
contamination. Ensure the Valve material is not hardened,
distorted, and/or warped. Replace the Valve if questionable.
Reinstall the Cover. Guidance, applicable O&M manual.

PROCEDURES

SIDE BLOCK/DEMAND REGULATOR

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 22
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
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.
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 applicable O&M manual.

2. Remove the Regulator Cover Clamp, Cover, and Diaphragm.

Visually inspect the interior of the Regulator Body for corrosion
and/or contamination. Clean as necessary. Guidance applicable
O&M manual.

3. Carefully inspect the Diaphragm for cuts, tears, and/or

deterioration. If any damage is found, replace the Diaphragm.
Guidance applicable O&M manual.

4. Carefully check the Regulator Exhaust Valve for warping,

distortion, stiffness, and/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 and/or
deterioration, replace the Valve. Guidance applicable 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 applicable O&M manual.
Reinstall the Diaphragm, the Cover, and the Clamp.

6. Depress the Purge Button. The Button should travel 1/16 1/8
before gas starts to flow and a strong purge should be felt when the
Button is fully depressed. If the Regulator Purge travel is less than
1/16 or greater than 1/8 , readjust the Lever. Guidance O&M
manual.
7. Check the Steady Flow Valve for proper operation.

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 23
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
NOTE: The Steady Flow Valve will rotate approximately two
complete 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 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.
PROCEDURES INITIALS

EMERGENCY GAS SUPPLY (EGS)

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,
and/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.
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.
Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 24
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
7. Inspect the Harness Assembly for signs of wear or damage.
Repair/replace as necessary.

Technician Signature:___________________________Date:___________________

Comments:___________________________________________________________

____________________________________________________________________

____________________________________________________________________

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 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].

NOTE: The Maintenance Log, Appendix 3, of the Operations and Maintenance Manual
may be used as a template for creating blank pages to record all the maintenance
performed

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 25
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
 KIRBY MORGAN SUPERLITE DEEP SEA DIVING HELMET MODELS
17A/B, 17C, 17K, 27, AND KM-37, KM-47, KM-57, KM-77
HELMET AND EMERGENCY GAS SYSTEM
DAILY SET-UP AND FUNCTIONAL CHECKLIST
APPENDIX A2.3
4-14-09

THIS DAILY SET-UP AND FUNCTIONAL CHECKLIST SHOULD BE COMPLETED PRIOR TO COMMENCEMENT
OF DAILY DIVING OPERATIONS OR AT LEAST ONCE A DAY IF BEING USED DURING CONTINUOUS DIVING.

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.
WARNING: These are recommended minimum checks when using Kirby Morgan
Helmets or Masks. Additional checks may be required as dictated by the
conditions and tasks being performed. Failure to perform in-water
checks may result in serious injury or death.
CAUTION: All diving conducted using Kirby Morgan Helmets or Band Masks must
include the use of a fully functional, properly maintained Emergency Gas
System ( EGS ). The EGS should be maintained in accordance with the
applicable Operations and Maintenance Manual(s).
NOTE: Steps 3(a) - 3(d) use the EGS for setting up and checking the Helmet
systems. For a proper check of the Demand Regulator adjustment, the
First Stage Regulator must have an intermediate supply pressure output
between 135 150 psig (9.3 10.3 bar). The First Stage Bleed/Relief
Valve should be set between 180 - 200 psig (12.4 13.8 bar). Do not
attach the Umbilical until Step 6.

Date:

Helmet Serial #:

Associated Equipment Serial #(s):

Technician (print name):

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 26
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
 STEP PROCEDURES INITIALS

SL-17 A/B YOKE / NECK CLAMP ASSEMBLY STEP 1.1

Helmet Attachment Components

Note: For SL-17K, SL-17C, SL-27, KM-37, KM-47, KM-57, KM-77 skip to step 1.2

WARNING: Anytime Helmets and Neck Clamps / Yoke Assemblies are mixed, the
Neck Clamp must be checked for proper function, fit and adjustment
prior to diving.
1.1 Yoke/Neck Diver/Tender- Check the following (a - c):
Clamp Assembly a. Visually inspect the Yoke/Neck Clamp
SL-17 A/B Assembly for signs of damage. Check the
Neck Dam for tears, holes, and/or cuts.
Ensure the Neck Dam is of the proper size
Note: Applicable to and fit.
SL-17 A/B ONLY. b. Test-mate the Yoke Assembly to the Helmet
For all other and check for proper Neck Clamp adjustment.
helmet models If adjustment is necessary, use a 7/16 open-
skip to step 1.2 end wrench on Nut (4) as a back-up wrench
and a 7/16 deep well socket with a torque
wrench and ensure Lock Nut (6) is torqued to
40 inch lbs. Repair/replace and/or adjust
parts as necessary. Guidance O&M Manual
c. Ensure the Latch Catch Assembly works
properly, is not bent or deformed. Also check
that the Safety Pin is present and attached
with lanyard. Guidance O&M Manual

1.2 Neck Dam Ring

Assembly
Diver/Tender Check the following (a-d):
17K, 17C, 27, KM-
37, 47, 57, 77
a. Visually inspect the Neck Dam Ring Assembly
for signs of damage. Check the Neck for tears,
holes, and/or cuts. Ensure the Neck Dam is of
the proper size and fit.
b. Lightly lubricate the Neck Ring O-ring if the
O-ring appears dry.

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 27
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
 STEP PROCEDURES INITIALS
c. Test-mate the Neck Dam Ring Assembly to the
Helmet and check for proper adjustment.
d. Ensure the sealed Pull Pins work properly.
2. Visually Inspect
Diver/Tender- Check the following (a - d):
the Helmet
a. Visually inspect Helmet Shell interior and
exterior for damage and/or contamination.
Check that the Oral Nasal Valve is correctly
installed and the Oral Nasal Mask is installed
on the Regulator Mount Nut. Ensure the
Nose Clearing Device operates smoothly.
Lubricate as necessary. Guidance O&M
Manual.
b. Ensure the Earphones and Microphones are
installed correctly. Guidance applicable
O&M Manual.
c. Inspect the Head Cushion for proper fit,
broken snaps, tears, and/or rips. Guidance
applicable O&M Manual.
d. Check the O-ring at the base of the Helmet for
signs of damage. Ensure the O-ring is lightly
lubricated. (SL-17 A/B only)
3. EGS Inspection Diver/Tender- Check the following (a - d):
NOTE: The EGS a. Visually inspect all EGS Hoses for signs of
being used damage.
must be b. Check the hydro date and ensure the cylinder
properly is within the VIP and the hydrostatic date.
maintained and Visually inspect the cylinder and valve for
fully obvious signs of damage.
functional. c. Ensure the First Stage Regulator pressure and
the Over-Pressure Bleed/Relief Valve settings
have been checked within the past month.
d. Inspect the Safety Harness and Cylinder
Retainer for wear and/or damage.
Repair/replace as necessary.

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 28
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
4. Check the Helmet Diver/Tender- Check the following (a - f):
EGS a. Orally check the One-Way Valve. Guidance
O&M Manual.
b. Connect the First Stage Regulator to the EGS
Cylinder and the Helmet Emergency Supply
Valve. With the cylinder turned OFF, open
and close the Side Block Emergency Valve to
check for smooth operation. Then open and
close the Steady Flow/Defogger Valve to
verify smooth operation.
c. Rotate the Regulator Adjustment Knob in fully
(clockwise), then rotate out (counterclockwise)
3 4 rotations to check for smooth operation.
d. Open the EGS Supply Valve on the cylinder.
Log the pressure _______ psig. Next open
the Emergency Supply Valve on the Side
Block.
e. Momentarily open the Helmet Steady Flow
3/4 to 1 full turn. Check for a strong flow of
gas out of the Defogging Train, and then
close.
f. Check for gas escaping from the One-Way
Valve. If any gas flow is detected the One-Way
valve should be overhauled or replaced.

5. Check the Demand Diver/Tender- Check the following (a - d):

Regulator a. Rotate the Demand Regulator Adjustment
adjustment Knob out (counterclockwise) until a slight
free flow develops. Next rotate in
NOTE: If the Purge (clockwise) until the free flow stops.
Button travels b. Slowly depress the Purge Button to check for
further than excessive travel. The Purge Button should
1/8 before gas travel no less than 1/16 and no more than
starts flowing, 1/8 (1.5 3.0 mm) before gas flow is heard.
or has a weak c. Depress the Purge Button all the way and
flow of gas verify a strong surge of gas.

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 29
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
 when fully d. Ensure the Side Block Emergency Valve is
depressed, the shut and the Bail Out Cylinder Valve is open.
adjustment of Log the cylinder pressure ______________
the Regulator psig.
is necessary.
Guidance
O&M Manual.

6. Attach the Tender:

Umbilical Blow down the Umbilical and attach it to the
Umbilical Adapter on the One-Way Valve.
7. Check the Diver:
Communications Perform communications check.
8. Check the Hot Tender:
Water Supply (if Check hot water supply connections if applicable.
applicable)
9. Check the Dry Tender:
Suit Inflation Check the dry suit Inflation Hose Connection.
Hose (if Ensure the dry suit Inflation Valve and Exhaust
applicable) Valve function properly.
10. Tender-Check Tender:
the Entire Rig Soap and leak check the Helmet/Mask gas fittings
and connections including the EGS.
11. Neck Clamp pin Tender-Check to ensure the following
17A/B only
a. Neck Clamp properly adjusted and Safety
Locking Pin present.
b. Diver s Safety Harness is in good condition
c. Umbilical Strain Release.
d. EGS Hose Quick Disconnect in good working
order
e. Boots, gloves, knife, and other accessories.
12. Tender Note comments or discrepancies below in the
comments section. Log maintenance in the
applicable maintenance log.

Technician Signature:_____________________________Date:_____________________

Comments:______________________________________________________________

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 30
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
KMDSI strongly 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 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].

NOTE: The Maintenance Log, Appendix 3, of the Operations and Maintenance Manual may be
used as a template to create blank pages to record all the maintenance performed.

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 31
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
 KIRBY MORGAN SUPERLITE DEEP SEA DIVING HELMET MODEL
17A/B
SUPERVISORS EQUIPMENT CHECKS
PRIOR TO ENTRY INTO WATER
APPENDIX A2.4.1
10-21-09

NOTE: This checklist is intended to be used with both KMDSI SuperLite 17A and
B.

NOTE: Helmet(s) being used in polluted waters, or extreme environments, will

require inspection that is more frequent.

CAUTION: KMDSI strongly recommends the use of a Tender to assist the diver when
dressing-in . The Tender should ensure the Helmet Liner is fastened to
the Helmet Shell and the Chinstrap is properly fastened under the divers
chin, once the Helmet is donned. After closing the Yoke/Neck Clamp
Assembly, ensure that the safety pin is installed.

WARNING: These are recommended minimum checks when using Kirby Morgan
Helmets or Masks. Additional checks may be required as dictated by the
conditions and tasks being performed. Failure to perform in-water checks
may result in serious injury or death.

CAUTION: All surface supplied diving with Kirby Morgan Helmets must include a
fully functional, properly maintained Emergency Gas System ( EGS ).
The EGS should be maintained in accordance with the applicable
Operations and Maintenance Manual(s).

Date:

Helmet Serial #:

Associated Equipment Serial #(s):

Technician (print name):

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 32
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
 STEP PROCEDURES INITIALS
1. Supply Gas Supervisor:
a. Ensure gas to the diver.
2. Check Breathing Diver- Check the following (a - e):
System
a. Open and close the Steady-Flow Valve to
ensure proper operation.
b. Check breathing resistance. Set Demand
Regulator Adjustment Knob for minimum
inhalation effort.
c. Press Purge Button to check gas purge
function.
d. Ensure Nose Block Device slides freely.
e. Ensure Emergency Valve opens and closes
properly. Then, ensure Emergency Valve is
closed and the Bail Out Cylinder Valve is
open.
3. Check Diver:
Communications Perform communications check.
4. Check Hot Water Tender:
Supply (if Check hot water supply connections. Ensure
applicable) topside hot water supply has been switched to
diver and verify flow to hot water shroud and suit
(if used).
5. Check Dry Suit Tender:
Inflation Hose (if Check dry suit Inflation Hose Connection.
applicable) Ensure dry suit Inflation Valve and Exhaust
Valve function properly.

6. Check Entire Rig Tender:

Soap and leak check Helmet/Mask gas fittings
and connections, including Emergency Gas
System.

7. Check Diver s Entire Rig Supervisor/Tender- Check

adjustment/fit of the entire rig,
including the following (a f):
NOTE: On the SL-17A/B, this
procedure will ensure the a. On SuperLite 17 A/B, ensure the Rear
Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 33
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
 Neck Clamp w/Yoke Hinge Tab is fully engaged on the
Assembly is properly alignment sleeve. Using thumb on the
adjusted prior to descent. bottom of Regulator Body, and
middle finger on Neck Clamp, attempt
NOTE: All equipment must be to pop Neck Clamp w/Yoke
adjusted properly and Assembly from bottom rim of Helmet
functioning correctly. .
The Helmet/Mask must b. Diver s Safety Harness.
be breathing easily and
properly. c. Umbilical strain release.

d. EGS Hose Quick Disconnect.

e. Boots, gloves, knife, and other
accessories.

f. Helmet supply pressure, minimum

115 psig.
8. Check Breathing Diver:
Check to ensure helmet is
breathing properly.

Note: All equipment must be

adjusted properly and functioning
correctly. The Helmet/Mask must
be breathing easily and properly.

Technician Signature: _________________________________ Date: ____________

Comments:_____________________________________________________________

______________________________________________________________________

______________________________________________________________________

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).
Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 34
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
Persons performing repairs should retain 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].

NOTE: The Maintenance Log, Appendix 3, of the Operations and Maintenance Manual
may be used as a template to create blank pages to record all the maintenance
performed.

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 35
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
 KIRBY MORGAN SUPERLITE DEEP SEA DIVING HELMET MODELS
17C, 17K, 27, KM-37, 47, 57, 77
SUPERVISORS EQUIPMENT CHECKS
PRIOR TO ENTRY INTO WATER
APPENDIX A2.4.2
10-21-09

NOTE: This checklist is intended to be used with KMDSI SuperLite 17C, 17K, 27
and KM-37, 47, 57, 77.

NOTE: Helmet(s) being used in polluted waters, or extreme environments, will

require inspection that is more frequent.

CAUTION: KMDSI strongly recommends the use of a Tender to assist the diver when
dressing-in . The Tender should ensure the Helmet Liner is fastened to
the Helmet Shell and the Chinstrap is properly fastened under the divers
chin, once the Helmet is donned.

WARNING: These are recommended minimum checks when using Kirby Morgan
Helmets or Masks. Additional checks may be required as dictated by the
conditions and tasks being performed. Failure to perform in-water checks
may result in serious injury or death.

CAUTION: All surface supplied diving with Kirby Morgan Helmets must include a
fully functional, properly maintained Emergency Gas System ( EGS ).
The EGS should be maintained in accordance with the applicable
Operations and Maintenance Manual(s).

Date:

Helmet Serial #:

Associated Equipment Serial #(s):

Technician (print name):

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 36
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
 STEP PROCEDURES INITIALS
1. Supply Gas Supervisor:
a. Ensure gas to the diver.
2. Check Breathing Diver- Check the following (a - e):
System
a. Open and close the Steady-Flow Valve to
ensure proper operation.
b. Check breathing resistance. Set Demand
Regulator Adjustment Knob for minimum
inhalation effort.
c. Press Purge Button to check gas purge
function.
d. Ensure Nose Block Device slides freely.
e. Ensure Emergency Valve opens and closes
properly. Then, ensure Emergency Valve is
closed and the Bail Out Cylinder Valve is
open.

3. Check Diver:
Communications Perform communications check.
4. Check Hot Water Tender:
Supply (if Check hot water supply connections. Ensure
applicable) topside hot water supply has been switched to
diver and verify flow to hot water shroud and suit
(if used).

Tender:
5. Check Dry Suit
Check dry suit Inflation Hose Connection.
Inflation Hose (if
Ensure dry suit Inflation Valve and Exhaust
applicable)
Valve function properly.
6. Check Entire Rig Tender:
Soap and leak check Helmet/Mask gas fittings
and connections, including Emergency Gas
System.

7. Check Diver s Entire Rig Supervisor/Tender- Check

adjustment/fit of the entire rig,
Danger: Both Pull Pins including the following (a f):
must engage a. Ensure the sealed Pull Pins are fully
engaged on the base of the Helmet
Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 37
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
 correctly Or Ring into the Locking
the Neck Dam Collar/Neck Pad Assembly.
Ring Assembly
could flood. b. Diver s Safety Harness.
Drowning may
c. Umbilical strain release.
result.
d. EGS Hose Quick Disconnect
Attempt to rotate pull pins, if
pin rotates this is an e. Boots, gloves, knife, and other
indication that pin is accessories
not correctly engaged f. Helmet supply pressure, minimum
115 psig (7.93 bar).
8. Check Breathing Diver:
Check to ensure helmet is
breathing properly.

Note: All equipment must be

adjusted properly and functioning
correctly. The Helmet/Mask must
be breathing easily and properly.

Technician Signature: _________________________________ Date: ____________

Comments:_____________________________________________________________

______________________________________________________________________

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 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].

NOTE: The Maintenance Log, Appendix 3, of the Operations and Maintenance Manual
may be used as a template to create blank pages to record all the maintenance
performed.
Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 38
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
 KIRBY MORGAN SUPERLITE DEEP SEA DIVING HELMET MODELS
17A/B, 17C, 17K, 27, KM-37, 47, 57, 77
SUPERVISORS IN-WATER CHECKS
APPENDIX A2.5

4-14-09

WARNING: These are recommended minimum checks when using Kirby Morgan
Helmets or Masks. Additional checks may be required as dictated by the
conditions and tasks being performed. Failure to perform in-water checks
may result in serious injury or death. See Chapter 2 of the KMDSI
SuperLite 17A/B Operations and Maintenance Manual for air supply
requirements.
CAUTION: Diving with Kirby Morgan Helmets must include a fully functional,
properly maintained Emergency Gas System ( EGS ). The EGS should
be maintained in accordance with the applicable Operations and
Maintenance Manual(s).
WARNING: If diving is conducted with less than the minimum recommended supply
pressure, the diver must tailor the work to prevent over breathing the
system, resulting in exhaustion.

Date:

Helmet Serial #:

Associated Equipment Serial #(s):

Technician (print name):

STEP PROCEDURES INITIALS

1. Check Breathing Diver:

Ensure Helmet is breathing properly. Set
the Demand Regulator Adjustment Knob
for minimum inhalation effort. Report:
Breathing OK

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 39
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
 STEP PROCEDURES INITIALS
2. Check Helmet/Equipment Diver:
for Leaks Ensure Helmet/Mask is watertight.
NOTE: If the diver is wearing a dry suit,
diver reports that a proper seal has been
made after checking for water leakage.
3. Maintain Gas Supply Console Operator:
Over-Bottom Pressure Maintain minimum over-bottom gas
supply pressure for depth (fsw x 0.445) +
NOTE: If the above over- required over bottom for depth, in
bottom pressure cannot accordance with the applicable O & M
be supplied, the diver Manual for the type of supply system.
will have to tailor his
workload to avoid Required over-bottom for depth:
exhaustion. 0 - 60 fsw (0 - 18.3 msw), 90 psig (6.2 bar)
NOTE: The Demand 61 - l00 fsw (18.6 - 30.5 msw), 115 psig
Regulator and Side (7.9 bar)
Block Assembly have a 101 - 132 fsw (30.8 - 40.2 msw), 135 psig
maximum design (9.3 bar)
pressure of 250 psig 133 -165 fsw (40.6 - 50.3 msw), 165 psig
(17 bar) over-bottom. (11.4 bar)
166 -220 fsw (50.6 - 67.1 msw), 225 psig
(15.5 bar)

Technician Signature:__________________________________Date:_______________

Comments:______________________________________________________________

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 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].

NOTE: The Maintenance Log, Appendix 3, of the Operations and Maintenance Manual may be used as a
template to create blank pages to record all the maintenance performed.

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 40
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
 KIRBY MORGAN SUPERLITE DEEP SEA DIVING HELMET MODELS
17A/B, 17C, 17K, 27, KM-37, 47, 57, 77
POST DIVE CLEANING, MAINTENANCE, AND INSPECTION CHECKLIST
APPENDIX A2.6
4-14-09

Post dive cleaning and inspection should be performed at the end of daily diving
operations or at least every 24 hours during continuous diving operation.
NOTE: Helmet(s) being used in polluted waters, or extreme environments, will
require more frequent cleaning, inspection and maintenance.
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.
NOTE: This cleaning and maintenance schedule is recommended for all SuperLite
Helmets and KM-37 and should be performed at least on a DAILY basis.
NOTE: Detailed instructions are located in the applicable O & M Manual.

Date:

Helmet Serial #:

Associated Equipment Serial #(s):

Technician (print name):

PROCEDURES INITIALS

1. Secure and bleed down gas supplies.

2. Disconnect and cap (or bag and tape) the Helmet Gas Connections and
disconnect the communication wires. Cap (or bag and tape) the
Umbilical End.

3. Wash the exterior surface of the Helmet with a solution of mild

detergent and fresh water, then rinse. Inspect for signs of damage.

4. Remove the Head Cushion Assembly. Inspect for damage. If the Head
Cushion has gotten wet with perspiration or water, clean and hang-up
for drying or airing.
Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 41
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
5. Remove the Demand Regulator Clamp, Cover, and Diaphragm
Assembly. Wash the interior of the Demand Regulator with mild
detergent and fresh water, then rinse thoroughly.
6. Dislodge the earphones. If the interior of the Helmet and Liner has
gotten wet, remove the earphone protective covers, wash with mild
detergent solution, rinse with fresh water and allow to dry.

7. Remove the microphone from the Oral Nasal Mask. Wash with a mild
detergent solution and rinse with fresh water.

8. Wipe interior of the Helmet, including the Oral Nasal Mask. Wash
with a mild detergent solution and rinse with fresh water. For
sanitizing procedures, refer to Appendix 5: Quick Sanitizing
Procedure.

9. Rotate the Regulator Adjustment Knob fully out (counter clockwise).

Close the Emergency Supply and Steady Flow Valves.

10. Clean the Neck Dam and Neck Clamp and Latch Catch (SL-17A/B
Assembly with a mild detergent solution. Operate the Neck Clamp
and Latch Catch (SL-17A/B), rinse with fresh water. Clean the Neck
Ring, and Pull Pin Assemblies (SL17K, 17C, 27, KM-37, 47, 57, 77)
with mild detergent solution, thoroughly rinse with fresh water.
11. Wipe all surfaces with a clean, dry towel to remove water droplets.
Allow to air dry.

12. Cap (or bag and tape) the Emergency Gas Whip on the First Stage
Regulator. Wash the exterior of all EGS components, the First Stage
Regulator, the Gas Cylinder, the Submersible Pressure Gauge, and
the Harness Assembly with a mild detergent solution and rinse with
fresh water.

13. Note any damage or discrepancies found during cleaning.

Technician Signature:___________________________________ Date:_____________

Comments:______________________________________________________________

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 42
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
_______________________________________________________________________

_______________________________________________________________________

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 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].
NOTE: The Maintenance Log, Appendix 3, may be used as a template to create blank
pages to record all the maintenance performed.

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 43
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
 BLEED/RELIEF VALVE
CLEANING INSPECTION AND OVERHAUL PROCEDURES
Appendix 4
4-14-09

The bleed/relief valve should be disassembled, cleaned, and inspected at least once a year, and
anytime the valve fails monthly lift testing, or fails to maintain a seal when within the specified range. The
bleed/relief valve is easily cleaned 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 from Kirby Morgan Dive Systems Inc. (KMDSI). Normal replacement
parts include the o-ring, soft seat, spring, and hex nut. 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.

CLEANING:
Tools:
1/2 open-end wrench
1/8 Allen wrench
Nylon toothbrush
Vinegar
Fresh water
Mild dish detergent
Ultrasonic sink, if available
Magnifying glass
New valve body o-ring

WARNING: DO NOT use cleaning solvents (i.e. mineral spirits, bleach, etc.) when cleaning
the bleed/relief valve. The use of cleaning solvents may lead to failure of the bleed/relief
valve.

1. Secure gas pressure to the first stage regulator, then bleed off.

2. Remove the bleed/relief valve from the regulator body using the 1/2 open-end wrench.

3. Remove, cut, and discard the bleed/relief valve body o-ring.

4. Using the 1/2 open-end wrench to hold the bleed/relief 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 nut, if either part is excessively corroded or shows signs of wear

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 44
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
 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.

NOTE: A deep groove in the soft seat is normal. Replacement is only necessary if the
rubber seat is deteriorated, cut, and/or chipped.

REASSEMBLY:
1. After cleaning, inspection and/or parts replacement reassemble the valve by installing the soft seat,
spring, and adjustment nut. Screw the adjustment nut down until it is approximately 1/2 thread from
being flush with the top of the valve body.
2. Lightly lubricate a new o-ring, then install on the valve body.
3. Test the bleed/relief valve according to the test procedure below.

LIFT CHECK/SETTING THE BLEED/RELIEF VALVE:

Tools required:
Adjustable first stage scuba regulator or controlled adjustable pressure source
Intermediate test gauge
1/2 open-end wrench
1/8 Allen wrench
HP air source at least 500 psig (34.4 bar).
Mild dish detergent
The purpose of lift checking the bleed/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 bleed/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). This procedure explains the steps necessary for
readjusting the bleed/relief valve after it is cleaned, overhauled or any time the valve is tested.

CAUTION: Ensure the bleed/relief valve is only installed in a low-pressure port of the first stage
regulator.
DANGER: Do not use oxygen, or mixed gas containing more than 23% oxygen by volume, for
lift checking the bleed/relief valve. The use of oxygen, or mixed gas, in a high-
pressure supply system not designed and cleaned for oxygen service, can result in a
fire or explosion causing serious injury or death.
NOTE: The bleed/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. 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.

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 45
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
1. Install the bleed/relief valve in a low-pressure port on an adjustable first stage regulator, or install on a
scuba test stand that has an adjustable pressure supply, then tighten with the 1/2 open-end wrench.
2. Install an intermediate pressure gauge in one of the low-pressure ports of the first stage regulator.
3. Install the first stage regulator on the cylinder. Ensure the bleed/relief valve and intermediate pressure
gauge are attached to low-pressure ports facing up.
4. Wet the bleed/relief valve with soapy water to help indicate when gas flow starts.
5. Slightly crack open the gas supply so a very slight flow of gas is traveling to the first stage, until the
intermediate pressure gauge travels no further. Leave the supply valve only slightly cracked open.
Most first stage regulators use an intermediate setting between 130 - 150 psig (9.3 10.3 bar).
6. Slowly, increase the intermediate setting of the first stage until the pressure gauge indicates 180 psig
(12.4 bar). If the bleed/relief valve starts venting before a pressure of 180 psig (12.4 bar) is reached (as
indicated by small bubbles forming or by popping ), turn the adjustment screw in (clockwise) using
the 1/8 Allen wrench on the bleed valve hex nut 1/16th -1/8th turn, or until all leakage stops as
indicated with the soapy water. If a pressure above 200 psig (13.8 bar) is reached with out the
bleed/relief valve forming bubbles or popping, slowly back out (counterclockwise) on the adjustment
hex nut 1/16th of a turn at a time until bubbles form.

NOTE: If the Allen screw on the bleed/relief valve hex nut is rotated too far, too fast, the
bleed/relief valve will pop open. This could possibly require the air to be secured at the
cylinder to reset the seat before the adjustment can be accomplished.

7. Continue this procedure as necessary until the bleed/relief valve consistently starts to forms bubbles at
a pressure between 180 and 200 psig (12.4 -13.8 bar). After the valve has been set to just bubble or pop
off, back out on the regulator adjustment nut until the pressure is set back to 135 psig (9.3 bar), or at
the factory setting of the first stage regulator.
8. Re-wet the bleed/relief valve, and then slowly increase the intermediate pressure on the first stage
regulator to recheck the lift pressure once more. The bleed/relief valve should start forming bubbles
between 180 - 200 psig (12.4 -13.8 bar) After final adjustment; reset the first stage regulator to 135
psig (9.3 bar), or to the manufacturer s recommended pressure setting. Spray the bleed/relief valve
with soapy water and ensure there are no leaks.
9. After a successful leak check, the bleed/relief valve may be reinstalled into the system.

NOTE: The bleed/relief valve can now be installed in any first stage regulator, providing the first
stage has an intermediate setting of 135 - 165 psig (9.3 11.4 bar).

TROUBLESHOOTING:
Problem:
Valve pops open and will not stop flowing:
Check:
If while setting the bleed/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 psig (9.3 bar), the valve continues to leak:

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 46
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
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. If, after
cleaning, the problem persists, replace the soft seat and spring and retest the unit. If, after this has been
accomplished, the seat continues to leak, then replacement of the complete valve will be necessary.

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 47
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
 QUICK SANITIZING PROCEDURE
Appendix 5
4-14-09

The purpose of this procedure is to sanitize the components directly exposed to each
diver s mouth and nose to help eliminate germs. KMDSI recommends sanitizing after
each diver when in use by multiple divers, and after each diving day when used by a
single diver. To accomplish this properly, all components exposed to the diver s
breathing should be sanitized. On the Helmets and KMB Band Masks, this will include
the Oral Nasal Mask and internal cavity of the Demand Regulator. For best results, the
Demand Regulator Cover and Diaphragm should be removed so the interior surfaces, as
well as the Diaphragm, can be properly exposed to the cleaning solution and rinse
water.

CAUTION: Carefully dilute germicidal cleansing solutions 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.

Listed below are four solutions, used by the U.S. Militaries, which have proven to be
effective when used in accordance with the manufacturer s recommendations. If no
other solutions are available, a solution of mild dish detergent and water and hand
scrubbing with a soft brush or rag can be done. Note: to maximize germ killing, solutions
should remain in contact with components for a minimum of 10 minutes.

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

2. Advance TBE: P/N: AD160 (spray) or AD1128 (gallon), Infection Control

Technology available): Ready to use.
Infection Control Technology
1751 So. Redwood Rd.
Woodscross, UT 84087 USA
1-800-551-0735

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 48
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
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 and Demand Regulator: For disassembly and reassembly
procedures, refer to the appropriate KMDSI Operations and Maintenance Manual.

1) Wet or immerse all components to be sanitized. Allow to stay in contact with the
solution for at least 10 minutes while lightly scrubbing over the components with a
nylon toothbrush or clean dishrag to help remove mucus or saliva build up.

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 while
brushing or rubbing.

4) If the equipment is not being used immediately, allow the components to air dry or pat
dry with a clean towel and reassemble.

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 49
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
 KMDSI Operator / User Training
KMB 18/28
Student Enabling Objectives
7-12-06

STUDENT ENABLING OBJECTIVES

Perform set-up, adjustment and pre-dive functional inspection procedures for Kirby
Morgan Band Masks; KMB 18 and KMB 28 in accordance with the applicable
Operations and Maintenance Manuals and the following checklists:

A2.2 Monthly Maintenance

A2.3 Daily Set-up and Functional Checklist
A2.4 Supervisor s Equipment Checks Prior to Entry
A2.5 Supervisor s Equipment Checks In-Water
A2.6 Post Dive Cleaning

HOOD SPIDER and RETAINING CLAMP

Upon instruction of this section the student will be able to:

a) Describe/perform a proper inspection of the Hood Assembly
b) Describe/perform a thorough inspection of the Spider Assembly
c) Describe/Perform a though inspection of the Clamp Assembly.
d) Explain what conditions will hasten aging of the Hood and Spider rubber
components.

FRAME COMPONENT ASSEMBLY

Upon instruction of this section the student will be able to:

a) Explain/demonstrate a proper visual inspection of the Frame Assembly.
b) Explain the physical and material differences between the KMB 18 and KMB
28.
c) Explain the Monthly, and Daily maintenance.
d) Explain the purpose of the Oral Nasal Mask and Valve Assembly and the
reason a correctly installed Valve is in the sealing surface out position. The
student will also be able to elaborate upon the dangers involved with
incorrectly installing the Valve, not using genuine KMDSI parts, or just not
having an Oral Nasal Mask or Valve installed.
e) Demonstrate proper inspection of the Whisker Assembly.
f) State the advantages/disadvantages and limitations of the double exhaust and
the reasons.
g) Conduct an inspection on the Defogger and EGS Valves and explain flats
and be able to point out what to look for regarding the serviceability of the
control knobs.
Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 50
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
 h) Perform Main Exhaust/Water Dump Valve inspection, thoroughly describing,
seating surface .
i) Describe/perform proper inspection or required maintenance of
communications system.

SIDE BLOCK/DEMAND REGULATOR

Upon instruction of this section the student will be able to:

a) Demonstrate/perform the two different ways of checking the One-Way Valve
and explain which test is the most stringent and why.
b) Demonstrate how to remove the Demand Regulator Cover to inspect, clean in
accordance with recommended procedure, inspect and re-assemble, adjust, fine
tune.
c) Demonstrate how to properly perform an inspection on the Demand Regulator
Diaphragm and state satisfactory criteria.
d) Explain the purpose/reason for cleaning Oral Nasal Mask and Demand
Regulator components with germicidal cleaning solutions.

EMERGENCY GAS SUPPLY

Upon instruction of this section the student will be able to:

a) Conduct a thorough inspection of all EGS components including the
maintenance records to ensure maintenance is in compliance with
manufacturers recommendations.
b) Demonstrate/perform both testing and adjusting on the First Stage Over-
Pressure Relief Valve.
c) Check/demonstrate/perform the correct recommended setting of the Over-
Bottom of the First Stage Regulator for the Emergency Gas Supply (EGS)
Cylinder.
d) Demonstrate/perform proper inspections of Harness Assembly, pointing out
trouble areas of high wear.

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 51
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
 KMB 18/28 (BANDMASK)
MONTHLY MASK INSPECTION
APPENDIX A2.2
4-14-09

This inspection is the minimum recommended maintenance and should be performed at

least ONCE A MONTH with Mask(s) in continuous use (used for more than 20 diving
days in a month) or at least every TWO (2) MONTHS, with Mask(s) used less than 10
diving days a month.
NOTE: Mask(s) being used in polluted waters, or extreme environments, will require
more frequent inspection.
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.
NOTE: Perform the 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.

Date:
Mask Serial #:

Associated Equipment Serial #(s):

Technician (print name):

PROCEDURES INITIALS

HOOD ASSEMBLY

1. Remove the Earphones from their pockets in the Hood. Remove the
Hood (2) from the Mask. Perform a visual inspection of all
components. Guidance O & M Manual.

PROCEDURES
2. Visually inspect all metal parts of the Band Assembly, band keeper,
components, including the Band Screws, for damage. Replace if
necessary. Guidance O & M Manual.

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 52
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
3. Visually inspect the Hood for signs of damage and/or deterioration.
Guidance O & M Manual.
4. Check the Head Harness (Spider) for signs of tearing, deterioration,
and/or damage. Ensure all five legs of the Spider are present.
Guidance O & M Manual.
MASK ASSEMBLY
1. Visually inspect the Mask exterior for loose and/or missing fasteners
and obvious signs of fiberglass damage; including cracks, gouges or
depressions.
NOTE: On the KMB-18, any gouges in the fiberglass shell deeper than
1/16 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. Any cracks or
depressions with fractures must be checked by an Authorized
KMDSI Repair Facility.

2. Remove the Covers from the Earphones. Remove Microphone from

Oral Nasal Mask. Inspect and repair/replace as necessary. Perform a
communications check. Guidance O & M Manual.

CAUTION: The Nose Block device MUST be replaced when installing a

new Oral Nasal Mask. Stretching the Oral Nasal Mask over the
Nose Block Device can cause the Oral Nasal Mask to tear.

3. Remove the Nose Clearing Device and Oral Nasal Mask. Remove the
Oral Nasal Valve as an assembly. Clean the Valve and the Valve Body
as an assembly. Clean the Oral Nasal Mask. Inspect Mask and Valve
Assembly for damage and/or deterioration. Replace the Oral Nasal
Mask if any damage is found. Replace the Oral Nasal Valve if it
appears dried, stiff, and/or does not lay flat. Clean and inspect the Nose
Clearing Pad, Shaft and O-rings for wear. Replace the Pad if
deteriorated or damaged. Replace O-rings if worn. Lightly lubricate
the Shaft O-rings and Shaft, then reinstall. Reinstall Oral Nasal Mask
and Valve Assembly. Guidance O & M Manual.

PROCEDURES

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 53
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
4. Remove the Comfort Insert (14) [KMB 18 only]. Clean and inspect the
Comfort Insert for damage and/or deterioration. Mark N/A for
KMB28
5. Without air to the Side Block, check the operation of the Defogger and
Auxiliary Supply Valve (EGS). If the Valves do not operate smoothly,
they must be overhauled or replaced. Guidance O & M Manual.
6. Remove the Main Exhaust Valve Cover. Inspect the Main
Exhaust/Dewatering Valve and Seat for damage and/or contamination.
Ensure the Valve material is not hardened, distorted, and/or warped.
Replace the Valve if questionable. Reinstall the Cover.

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. No
gas should be drawn thru the One-Way Valve.
2. Remove the Regulator Cover Clamp, Cover, and Diaphragm. Visually
inspect the interior of the Regulator Body for corrosion and/or
contamination. Clean as necessary. Guidance O & M Manual.
3. Carefully inspect the Diaphragm for cuts, tears, and deterioration. If any
damage is found, replace the Diaphragm.
4. Carefully check the Regulator Exhaust Valve for warping, distortion,
stiffness, and/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 and/or deterioration, replace the
Valve. Guidance 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. Reinstall the Diaphragm, the Cover, and the Clamp.
Guidance O & M Manual.

PROCEDURES

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 54
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
6. Depress the Purge Button. The Button should travel 1/16 1/8
before gas starts to flow and a strong purge should be felt when the
Button is fully depressed. If the Regulator Purge travel is less than
1/16 or greater than 1/8 , readjust the Lever. Guidance O & M
Manual.
7. Check the Steady Flow Valve for proper operation.
NOTE: The Steady Flow Valve will rotate approximately two complete
revolutions from closed to full open. With the air pressure to the
Mask between 135 - 150 psig (9.3 - 10.3 bar), turning the Steady
Flow Valve one full rotation should result in a strong flow of gas
through the Defogger Train.
8. Secure the gas supply, then bleed down and remove the gas supply 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.
PROCEDURES INITIALS

EMERGENCY GAS SUPPLY (EGS)

NOTE: The Emergency Gas System consists of a good quality First Stage
Regulator equipped with a submersible pressure gauge, an Over
Pressure Bleed/Relief Valve, and an Emergency Gas Supply Hose
that connects to the Emergency Valve on the Mask Side Block.
1. Check the hydrostatic date and last visual inspection record ( VIP ) of
the cylinder. Ensure date(s) are within the specified range. The VIP is
done at least annually and the hydrostatic test is done at least every five
years.
2. Check the maintenance record of the EGS components to ensure the
First Stage Regulator s maintenance has been performed in accordance
with the manufacturer s recommendations.
3. Check all Hoses for signs of blisters, cover slippage, cuts, and/or
abrasions. Replace any Hose(s) that show signs of leakage/damage. If
a Quick Connect EGS hose is being used, inspect quick connect and
fittings for signs of wear/damage.

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 55
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
4. If a submersible pressure gauge is used, ensure it has been compared to
a gauge of known accuracy.

5. Test the First Stage Bleed/Relief Valve. Guidance per Appendix

4:Bleed/Relief Valve Cleaning, Inspection, and Overhaul Procedures .
6. Log the lifting pressure __________ psig.
NOTE: An adjustable First Stage Regulator and a Gas Cylinder with a
minimum of 500 psig (34.5 bar) available are required for this step.
NOTE: The Bleed/Relief Valve should be adjusted to start relieve between
180 - 200 psig (12.4 13.8 bar) when tested.
7. Check the over-bottom setting of the First Stage Regulator to ensure it
is within the manufacturer s specified pressure range. For KMDSI
Helmets and Masks, the minimum over-bottom for the emergency
supply is 135 psig (9.3 bar) and the maximum 165 psig (11.4 bar).
Log the intermediate pressure.
8. Perform a leak check of all EGS components and fittings using soapy
water in a pressurized condition. Repair/replace items as necessary.
9. Inspect the Harness Assembly for signs of wear and/or damage.
Repair/replace as necessary.

Technician Signature:____________________________ Date:__________________

Comments:___________________________________________________________
____________________________________________________________________

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 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].

NOTE: The Maintenance Log, Appendix 3, of the Operations and Maintenance Manual
may be used as a template for creating blank pages to record all the maintenance
performed.

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 56
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
 KMB 18/28 (BAND MASK)
DAILY MASK AND EMERGENCY GAS SYSTEM
SET-UP AND FUNCTIONAL CHECKLISTS
APPENDIX A2.3
4-14-09

THIS DAILY SET-UP AND FUNCTIONAL CHECKLIST SHOULD BE COMPLETED PRIOR TO COMMENCEMENT
OF DAILY DIVING OPERATIONS AND AT LEAST EVERY 24 HOURS IF IN CONTINUOUS USE.

WARNING:
These are recommended minimum checks when using Kirby Morgan KMB
18/28 Band Masks. Additional checks may be required as dictated by the
conditions and tasks being performed. Failure to perform in-water checks
may result in serious injury or death.

NOTE: Mask(s) being used in polluted waters, or extreme environments, will require
more frequent inspection.
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.
NOTE: Perform the 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.
NOTE: Steps 3(a) - 3(e) use the EGS for setting up and checking the Mask s systems.
For a proper check of the Demand Regulator adjustment, the First Stage
Regulator must have an intermediate supply pressure output between 135 150
psig (9.3 10.3 bar). The First Stage Bleed/Relief Valve should be set between
180 - 200 psig (12.4 13.8 bar). Do not attach the Umbilical until Step 6.

Date:

Mask Serial #:

Associated Equipment Serial #(s):

Technician (print name):

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 57
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
 STEP PROCEDURES INITIALS

1. Hood and Band Diver/Tender: Check the following (a-d):

Assembly a. Visually inspect the Hood and Face Seal for
NOTE: When the signs of damage. Check the Hood for tears,
screws that holes, and/or cuts. Ensure the Face Seal is
hold the properly glued to the Hood.
Bands in b. Check the screws that hold the Bands in
position are position. They must be properly torque to 26
properly inch pounds (28 kg cm). If the old style non
torque, the band keeper hood is in use, ensure the Hood
Hood and protrudes at least to (6 12 mm).
Face Seal Guidance O & M Manual.
cannot be c. Inspect the Bands. Ensure the welds exhibit
removed no signs of cracking and/or parting. Inspect
from under all band keeper components
the Bands.
DANGER:
If the Bands become loose, the Hood and
Face Seal could separate from the Mask. This
would cause the Mask to flood, which could
cause drowning.
d. Inspect the Spider to ensure there are no tears
and/or cracks in the material. Ensure all five
legs are present. If it is worn and/or cracked,
it must be replaced.
2. Visually Inspect Diver/Tender: Check the following (a-g):
Mask a. Visually inspect the interior/exterior of the
Band Mask for any obvious signs of damage.
NOTE: KMDSI Check to make sure the Oral Nasal Valve is
recommends correctly installed and the Oral Nasal Mask is
replacement installed on the Regulator Mount Nut. Ensure
of the Hose the Nose Clearing Device operates smoothly.
Assembly Lubricate as necessary. Guidance O & M
(117a) on the Manual.
KMB-18A b. Ensure the Earphones and the Microphone are
every 2-years, installed correctly. Check the Wire Lugs to
regardless of ensure they are not touching each other.
condition. Guidance O & M Manual.
c. Ensure the Demand Regulator Cover is not
excessively dented, with dents deeper than
inch.
Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 58
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
 STEP PROCEDURES INITIALS

d. Inspect the Regulator Hose Assembly on the

KMB-18A. The Hose(s) and fittings must be
in good shape. On the KMB-18B, the Bent
Tube must not have any dents and/or
compressed areas exceeding 1/8
e. Check all moving parts to ensure smooth and
proper operation.
1) Defogger Control Knob
2) Auxiliary Knob (EGS)
3) Nose Block Device
4) Regulator Adjustment Knob
2. Visually Inspect f. Ensure the One-Way Valve is operational
Mask (Cont.)
WARNING: The One-Way Valve must be
NOTE: The EGS tested daily prior to commencing
being used diving operations. DO NOT DIVE
must be THE MASK if the One-Way Valve is
properly not operating properly. If the Hose
maintained parts near the surface, serious injury
and fully could result to the divers lungs
functional. and/or eyes. In extreme cases, this
could be fatal.
g. Connect the First Stage Regulator to the EGS
Cylinder and the Mask Emergency Supply
Valve. With the Cylinder turned OFF, open
and close the Side Block Auxiliary Valve
(EGS) to check for smooth operation. Then
open and close the Defogger Valve to check
for smooth operation. Guidance O&M Manual.
3. EGS Inspection
Diver/Tender: Check the following (a-e):
a. Visually inspect all EGS hoses for signs of
damage.
b. Check to ensure the cylinder is within the VIP
and the hydro dates.
c. Ensure the First Stage Regulator pressure
setting and the Over Pressure Bleed/Relief
Valve settings have been checked within the
past month. (Maintenance Log).
Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 59
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
 STEP PROCEDURES INITIALS

d. Inspect the Safety Harness and Cylinder

Retainer for wear and damage.
Repair/replace as necessary.
e. Document inspection/maintenance in
Maintenance Log (Appendix 3).
4. Check the Mask Diver/Tender: Check the following (a-d):
a. Rotate the Regulator Adjustment Knob in fully
(clockwise), then rotate out
(counterclockwise) 3 4 rotations to check
for smooth operation.
b. Open the EGS Supply Valve on the cylinder.
Log the pressure _______ psig. Then open
the Emergency Supply Valve on the Side
Block.
c. Momentarily open the Mask Defogger to 1
full turn. Check for a strong flow of gas out
of the Defogging Train, and then close.
d. Check for gas escaping from the One-Way
Valve.
5. Attach the Tender:
Umbilical Blow down the Umbilical and attach it to the
Umbilical Adapter on the One-Way Valve.

6. Check the Diver/Tender: Check the following (a-d):

Demand
a. Rotate out (counterclockwise) on the Demand
Regulator
Regulator Adjustment Knob until a slight free
Adjustment
flow develops. Then rotate in (clockwise)
until the free flow stops.
Note: If the Purge b. Slowly depress the Purge Button to check for
Button travels excessive travel. The Purge Button should
further than 1/8 travel in no less than 1/16 and out no more
(3mm) before than 1/8 (1.5 - 3.0 mm) before gas flow is
gas starts heard.
flowing, or has
c. Depress the Purge Button all the way, verify a
a weak flow of
strong surge of gas.

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 60
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
 STEP PROCEDURES INITIALS

gas when fully

depressed,
adjustment of the d. Ensure the Side Block Emergency Valve is
regulator is closed, and the Bail Out Cylinder Valve is
necessary. open. Log the cylinder pressure _____ psig.
Guidance O&M
Manual
7. Check the Diver:
Communications Perform communications check.
8. Check the Hot Tender:
Water Supply Check the hot water supply connections. Ensure
(if applicable) topside supply has been switched to the diver and
verify flow to hot water shroud and suit (if used).
9. Check the Dry Tender:
Suit Inflation Check the dry suit Inflation Hose Connection.
Hose (if Ensure the dry suit Inflation Valve and Exhaust
applicable) Valve function properly.
10. Check the Tender:
Entire Rig Soap and leak check the Mask gas fittings and
connections including the EGS.
11. Check the Supervisor/Tender: Check adjustment/fit of
Diver s Entire the entire rig, including the following (a-d):
Rig a. Diver s Safety Harness
b. Umbilical Strain Release
c. EGS Hose Quick Disconnect
d. Boots, gloves, knife, and other accessories

NOTE: All equipment must be adjusted

properly and functioning correctly.
12. Check Diver:
Breathing Check to ensure the Mask is breathing easily.

NOTE: The Mask must be breathing easily

and properly
13. Diver(s) Is Diver:
Ready Report when you are ready to enter the water.

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 61
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
Technician Signature:____________________________ Date:________________

Comments:_________________________________________________________

__________________________________________________________________

__________________________________________________________________

__________________________________________________________________

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 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].

NOTE: The Maintenance Log, Appendix 3, of the Operations and Maintenance Manual may be used as a template to
create blank pages to record all the maintenance performed.

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 62
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
 KMB 18/28 (BANDMASK)
SUPERVISORS EQUIPMENT CHECKS
PRIOR TO ENTRY INTO WATER
APPENDIX A2.4
7-12-06

NOTE: Helmet(s) being used in polluted waters, or extreme environments, will

require more frequent inspection.

CAUTION: KMDSI strongly recommends the use of a Tender to assist the diver when
dressing-in . The Tender should ensure the Helmet Liner is fastened to
the Helmet Shell and the Chinstrap is properly fastened under the divers
chin, once the Helmet is donned. Prior to closing the Yoke/Neck Clamp
Assembly, ensure that the Clamp is installed.

WARNING: These are recommended minimum checks when using Kirby Morgan
Helmets or Masks. Additional checks may be required as dictated by the
conditions and tasks being performed. Failure to perform in-water checks
may result in serious injury or death.

CAUTION: All surface supplied diving with Kirby Morgan Helmets must include a
fully functional, properly maintained Emergency Gas System ( EGS ).
The EGS should be maintained in accordance with the applicable
Operations and Maintenance Manual.

Date:

Helmet Serial #:

Associated Equipment Serial #(s):

Technician (print name):

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 63
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
 STEP PROCEDURE INITIALS
1. Check Breathing Diver - Check the following (a-e):
System
a. Open and close Steady Flow Valve to ensure proper
operation.
b. Check breathing resistance, adjust Demand Regulator
Adjustment Knob for minimum inhalation effort.
c. Press Purge Button to check gas purge function.

d. Ensure Nose Block Device slides freely.

e. Ensure Emergency Valve opens and closes properly, then
verify Emergency Valve is shut and the Bail Out Cylinder
Valve is open.
2. Check Diver:
Communications Perform communications check.
3. Check Hot Water
Tender:
Supply (if
Check the hot water supply connections. Ensure topside
applicable).
supply has been switched to the diver and verify flow to hot
water shroud and suit (if used).
4. Check the Dry
Suit Inflation Tender:
Hose (if Check the dry suit Inflation Hose Connection. Ensure the dry
applicable) suit Inflation Valve and Exhaust Valve function properly.

5. Check Entire Rig.

Tender:
Soap and leak check the Mask gas fittings and connections,
including the EGS.
6. Check the Diver s Supervisor/Tender - Check adjustment of entire rig,
Entire Rig including the following (a-e):
NOTE: All a. Diver s Safety Harness
equipment
must be b. Umbilical Strain Release
adjusted
properly and c. EGS Hose Quick Disconnect

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 64
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
 functioning
d. Boots or fins, gloves, knife, and other accessories
correctly.
e. Helmet supply pressure, minimum 115 psig.

7. Check Breathing Diver:

Check to ensure helmet is breathing easily.

NOTE: The Mask must be breathing easily and properly.

Technician Signature: _______________________________Date:__________________

Comments:______________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

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 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].

NOTE: The Maintenance Log, Appendix 3, of the Operations and Maintenance Manual
may be used as a template for creating blank pages to record all the maintenance
performed.

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 65
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
 KMB 18/28 (BANDMASK)
SUPERVISORS IN-WATER CHECKS
APPENDIX A2.5
4-14-09

NOTE: Mask(s) being used in polluted waters, or extreme environments, will

require more frequent inspection.
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.
WARNING: These are recommended minimum checks when using Kirby Morgan
Band Masks. Additional checks may be required as dictated by the
conditions and tasks being performed. Failure to perform in-water checks
may result in serious injury or death. See Chapter 2 of the KMDSI
SuperLite 17A/B Operations and Maintenance Manual for air supply
requirements.
CAUTION: All surface supplied diving with Kirby Morgan Band Mask(s) must
include a fully functional, properly maintained Emergency Gas System
( EGS ). The EGS should be maintained in accordance with the
applicable Operations and Maintenance Manual(s).
WARNING: If diving is conducted with less than the minimum recommended supply
pressure, the diver must tailor the work to prevent exhaustion.

Date:

Mask Serial #:

Associated Equipment Serial #(s):

Technician (print name):

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 66
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
 STEP PROCEDURE INITIALS

1. Check Breathing Diver:

Ensure Mask is breathing properly. Adjust the
Demand Regulator Adjustment Knob for easy
inhalation. Report: Breathing OK
2. Check Diver: Ensure Mask is watertight.
Mask/Equipment NOTE: If the diver is wearing a dry suit,
for Leaks diver reports that a proper seal has
been made after checking for water
leakage.
3. Maintain Gas Supply Console Operator:
Over-Bottom Maintain minimum over-bottom gas supply
Pressure pressure for depth (fsw x 0.445) + required
NOTE: If the above over-bottom for depth, in accordance with
over-bottom the applicable O & M manual for the type
pressure cannot of supply system.
be supplied, the
Required over-bottom for depth:
diver will have to
0 - 60 fsw (0 - 18.3 msw), 90 psig (6.2 bar)
tailor his
61 - l00 fsw (18.6 - 30.5 msw), 115 psig (7.9
workload to
bar)
avoid
101 - 132 fsw (30.8 - 40.2 msw), 135 psig (9.3
exhaustion.
bar)
NOTE: The Demand 133 -165 fsw (40.6 - 50.3 msw), 165 psig
Regulator and (11.4 bar)
Side Block 166 -220 fsw (50.6 - 67.1 msw), 225 psig
Assembly have a (15.5 bar)
maximum design
pressure of 250
psig (17 bar)
over-bottom.

Technician Signature:________________________________Date:_______________

Comments:____________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 67
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
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 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].
NOTE: The Maintenance Log, Appendix 3, may be used as a template to create blank
pages to record all the maintenance performed.

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 68
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
 KMB 18/28 (BANDMASK)
POST DIVE CLEANING
MAINTENANCE AND INSPECTION
APPENDIX A2.6
4-14-09

Post diving cleaning and inspection should be performed at end of daily diving operations
or at least every 24 hours if in continuous use.
NOTE: Mask(s) being used in polluted waters, or extreme environments, will
require more frequent inspection.
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.
NOTE: This cleaning and maintenance schedule is recommended to be performed
on a DAILY basis.
NOTE: Detailed instructions are located in Chapter 5.

Date:

Mask Serial #:

Associated Equipment Serial #(s):

Technician (print name):

PROCEDURES INITIALS

1. Secure and bleed down gas supplies.

2. Disconnect and cap (or bag and tape) the Mask Gas Connections
and disconnect the communication wires. Cap (or bag and tape)
the Umbilical End.
3. Wash the exterior surface of the Mask with a solution of mild
detergent and fresh water, then rinse. Inspect for signs of damage.

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 69
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
 PROCEDURES INITIALS

4. Dislodge the Earphones from their pockets in the Hood. Remove

the Earphone protective covers, clean and rinse to allow to dry.
5. Clean Hood Assembly. Rinse with fresh water and inspect for
damage. Hang-up for drying or airing.
6. Remove the Demand Regulator Clamp, Cover, and Diaphragm
Assembly. Wash the interior of the Demand Regulator with mild
detergent and fresh water, then rinse thoroughly.
NOTE: While rinsing the interior of the Demand Regulator DO NOT
depress the Purge Button. This action will introduce foreign
matter into the Inlet Valve and Seat.
7. Remove the Microphone from the Oral Nasal Mask. Avoid getting
water on the Oral Nasal Mask, Microphone and Earphones.
8. Wipe down interior of the Mask, including the Oral Nasal Mask
with a mild detergent and fresh water solution. Thoroughly rinse
with fresh water while cycling the Defogger Knob, Auxiliary Gas
Knob (EGS) and Regulator Adjustment Knob. For sanitizing
procedures, refer to Appendix 5: Quick Sanitizing Procedure.
9. Fully back out on the Regulator Adjustment Knob,
counterclockwise (this will prolong the life of the Inlet Valve
Seat). Shut the Auxiliary Supply (EGS) and Steady Flow Valves.
10. Wipe all surfaces with a clean dry towel to remove water droplets.
Allow to air dry.
11. Cap (or bag and tape) the Emergency Gas Whip on the First Stage
Regulator. Wash the exterior of all EGS components, the First
Stage Regulator, the Gas Cylinder, the submersible pressure
gauge, and the Harness Assembly with a mild detergent solution
and rinse with fresh water. Hang-up Harness Assembly for
drying or airing.

Technician Signature:_________________________________Date:______________

Comments:____________________________________________________________

_____________________________________________________________________

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 70
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100
Comments:______________________________________________________________

_______________________________________________________________________

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 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].
NOTE: The Maintenance Log, Appendix 3, of the Operations and Maintenance Manual
may be used as a template to create blank pages to record all the maintenance
performed.

Kirby Morgan, SuperLite, Band Mask, KMB Band Mask, EXO, SuperMask, SuperFlow, and Rex are all registered 71
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 1970-2009 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
Copyright 2003-2009, Dive Lab., Inc. All rights reserved. InspTrnG 03100