EXO Full-Face Mask Manual

STOP!
BEFORE GOING FURTHER-
This manual will refer to location numbers in specific drawings, or in the exploded view, which is
in the back of this manual. These numbers are called “location” numbers. They may be used to find
the referred to parts in the drawings in this manual only. They are not the part number. Next to the
exploded drawing is a list of the “location” numbers that match the Kirby Morgan part numbers
along with the name of the part. Always check the part number when ordering to make sure it is
correct. When ordering, always specify the helmet model number and serial number as well.

Chapter 1.0
General Information Regarding Kmdsi Products

1.1 Introduction
The Kirby Morgan Corporation was started in 1965.
The copper and brass “heavy gear” or “Standard
Dress” helmets were the first helmets manufactured by
the company. Over the years Kirby Morgan designed,
manufactured and sold many different helmets and
masks for commercial divers.

Staying active in commercial diving has contributed to

the successful design innovations of KMDSI products.
This may be the primary reason for the acceptance of
our designs by professional divers.

Bev Morgan has designed more than Fifty-Seven div-

ing helmets and over 40 diving masks. All employees
of KMDSI participate as part of the Kirby Morgan
design team. It would not be possible for us to supply
the commercial, military, scientific, and public service Bev Morgan, Chairman of the Board
diving industries with our equipment, without the team Kirby Morgan Dive Systems, Inc.
of people that make up Kirby Morgan Dive Systems,
Inc. (KMDSI)
Each piece of gear we manufacture has in it some of
We feel it is important for the reader to understand the thinking of those who have gone before us. To all
that we at KMDSI consider ourselves as only part those people who give something of themselves to the
of the process along the path in diving equipment men and women who work underwater, we express
design. We welcome all input from our customers. a thank you.
The thinking of many good divers, diving equipment
engineers, diving medical specialists, diving organiza- We have a strong commitment to providing the best
tion administrators and their supporting personnel has diving equipment and service possible. This thinking
contributed to the current state of the art of diving. has been the policy of Kirby Morgan Dive Systems,
Inc. and we will continue to take this approach to our
work.

Our extensive dealer network makes it easy to obtain

genuine Kirby Morgan replacement parts, as well as
technical assistance worldwide.

12 © Copyright 1970-2009 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080115002
 EXO Full-Face Mask Manual

KMDSI has always concentrated on designing and The models of Kirby Morgan diving helmets cur-
manufacturing diving equipment that allows most rently in production are the SuperLite-17B, MK-21
repairs, inspections, and all routine maintenance to (U.S. Navy version), the SuperLite-27,and the Kirby
be performed by the user. Most routine preventative Morgan 37, 47, 57 and 77. All are commercially rated
and corrective maintenance can be accomplished by and marked.
the user utilizing this manual, the KMDSI Tool Kit
(P/N 525-620) and common hand tools. Technician The SuperLite-17B was first developed in 1975 and
training is available through Dive Lab Inc., informa- quickly set a standard for diving helmet design. Many
tion can be obtained on line at www.divelab.com or large and small commercial diving companies, mili-
by telephone at 850-235-2715. tary organizations, scientific divers, and public safety
divers are successfully using this design around the
1.2 The Kirby Morgan Diving Helmets, Masks world.
& Air Control System
All Kirby Morgan diving helmets and masks are The SL-17B helmet system consists primarily of two
manufactured by Kirby Morgan Dive Systems, Inc. major components: the neck dam/yoke assembly, and
(KMDSI). Each step of the manufacturing process is the helmet. To don the helmet, the diver first slips the
carefully controlled to assure the customer of a high angled neck dam with the attached yoke over his head.
quality, durable helmet that will function properly for The helmet is lowered onto the diver’s head with the
many years. help of a tender, then the yoke hinge tab is hooked
onto the alignment screw on the rear weight. The neck
clamp is then slipped onto the helmet and locked.

LY RATED
IAL -
RC P
E

RO
ST E D C O M M

F
ESSIONAL D
TE

IV

SuperLite 17B Kirby Morgan 37

B

NG
I

A
EL GE
AR - DIV
™
™
™
approved and marked approved and marked
Yoke and Latch Catch Neck Pad and
Assembly Sealed Pull Pins.

© Copyright 1970-2009 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080115002 13
EXO Full-Face Mask Manual

The locking system not only seals the neck dam to the diver a comfortable, secure, custom fit.
helmet but also secures the front of the yoke, fastening
the helmet to the diver’s head.

The SuperLite-17A/B shares many common breath-

ing system parts with all Kirby Morgan helmets and
masks. The breathing system has been man-tested to
1600 FSW and approved by the U.S. Navy for surface-
supplied diving to 190 FSW with air and 300 FSW
with mixed gas. It surpasses all requirements of all
governing agencies and it is approved for commercial
diving through out the world.

Other features that are common to all Kirby Morgan

helmets and Band Masks include:
* Face port and retainer ring
* Communications components
* Oral/nasal mask
* Nose block device
* Air train defogger SuperLite 27
™

approved and marked

The Kirby Morgan 37 Commercial Diver’s Helmet
represents what we at Kirby Morgan considered to be
a turning point in modern diving helmet design. The Kirby Morgan 47
helmet consists of two major assemblies: the helmet
shell/helmet ring assembly and the neck dam/neck
ring assembly. IAL
LY RATED
-
RC P

RO
ST E D C O M M

F
ESSIONAL D
The helmet comes with the large tube SuperFlow 350
adjustable demand regulator which provides an easier

TE

IV
B
NG

I
A
EL

breathing gas flow during peak work output. A quick

GE
AR - DIV
™

change communications module is available with

either bare wire posts or a waterproof connector.
®
The helmet ring houses the sealed pull pins and pro- ™

vides protection for the bottom end of the helmet. approved and marked
The diver is also provided with an externally adjust- The Kirby Morgan 47 offers the ultimate in a high
able chin support. This custom fit and balance seats performance breathing regulator. This helmet has an
the helmet comfortably for long periods of time even entirely new breathing system, oral nasal mask, and
when working in the face down position. water ejection system. The Rex® Demand Valve (pat-
ents pending), with it’s fully adjustable balanced piston
The SuperLite 27 Commercial Diver’s Helmet has is a breakthrough design that exceeds the requirements
all the same features of the KM37 on a smaller, low of all government or other testing agencies.
volume shell design. This helmet is often preferred by
persons with smaller heads. It has the best work-of-breathing performance when
compared to ANY other commercial diving helmet.
The chrome plated machined brass helmet neck ring The Kirby Morgan 47 Dive Helmet has been tested
houses the sealed pull pins and provides protection and meets or exceeds European CE requirements and
for the bottom end of the helmet. Like the SL-17K, is fully commercially rated. In all other respects, this
37 and 17C, the diver is provided with an externally helmet is nearly identical to the Kirby Morgan 37.
adjustable chin support. This support, along with the
adjustable neck pad on the locking collar, gives the

14 © Copyright 1970-2009 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080115002
 EXO Full-Face Mask Manual

Kirby Morgan 77
Kirby Morgan 57

® ™

marked
®
The Kirby Morgan 57 helmet features our revolution- ™

ary SuperFlow 450 regulator. It's machined from a approved and marked
stainless steel casting for the ultimate in performance The Kirby Morgan 77 represents the first in a new
and reliability. This commercially rated regulator generation of stainless steel diving helmets that pro-
delivers all the breathing gas you need for the most vide an alternative for the diver who prefers a metal
demanding work underwater. helmet. The helmet features a stainless steel version
of our new REX® regulator, which offers the best
The Kirby Morgan 57 also includes our Quad- performance of any Kirby Morgan system.
Valve™ Exhaust System. It's recommended for div-
ing in biologically contaminated water, when you're It has the best work-of-breathing performance when
properly trained and equipped, using recommended compared to ANY other commercial diving helmet.
procedures. This new exhaust has exceptionally low The Kirby Morgan 77 Dive Helmet has been tested
exhalation resistance that you must experience to ap- and meets or exceeds European CE requirements and
preciate. is fully commercially rated.
D
The advantages of this all stainless steel helmet include
the following:

• No refinishing required if the surface is scratched

or gouged.

• Faster production of helmets for customer deliv-

ery.

• Elimination of threaded inserts for securing the port

retainer to the helmet shell.

• No need to remove the handle to remove the port

retainer.

• One piece sideblock includes both the free-flow valve

and the Emergency Gas System valve.

• The helmet ring is an integral part of the helmet.

© Copyright 1970-2009 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080115002 15
EXO Full-Face Mask Manual

The EXO Full Face Mask is designed for both

surface supplied and scuba diving. By enclosing the
divers eyes, nose and mouth, the EXO permits nearly
normal speech when used in conjunction with most
wireless, and all hardwire underwater communication
systems.

The ORIGINAL EXO (no longer produced) design

came with automatic defogging, no oral nasal mask or
nose block device (optional conversion kits available).
The mask frame was black.

The EXO BR (BALANCED REGULATOR) shown

here is designed to meet or exceed recommended
performance goals in both scuba and surface supplied
modes and is approved. It meets and surpasses
European standards for regulator performance.
KMB 18 A/B
™

approved and marked

The KMB 18B Band Mask frame is constructed of
hand laid fiberglass. The head harness is a molded,
strong tear resistant neoprene rubber.

The hood, which attaches to the mask frame with

welded stainless steel bands, provides warmth for the
divers head as well as pockets for the earphones. The
communications connections can be either a male
waterproof plug in type or bare wire posts. Both this
mask and the KMB 28B feature the new Tri-Valve™
Exhaust System.
EXO BR
The KMB 28B Band Mask (not shown) is very simi- approved and
™

marked
lar to the KMB 18, with many parts on the KMB 18B
being interchangeable with the KMB 28B. The major The Balanced Regulator helps reduce the work of
difference between the 18 and 28 is the material of the breathing for the diver by balancing the intermediate
mask frame itself. The KMB 18 has a fiberglass frame air pressure against the valve sealing pressure inside
(yellow) while the KMB 28B frame is an extremely the regulator. This enables the regulator to instantly
durable injection molded plastic (black). adjust to changes in line pressure. The Balanced Regu-
lator is adjustable for a wide range of intermediate
Other differences include: pressures between 100 PSI - 230 PSI.
1) The main exhaust body of the KMB 28 is part of the
frame itself and uses a #545-041 main exhaust cover Both models have a modular communications de-
2) no comfort insert is required on the 28 sign that permits rapid and simple maintenance. The
3) the face ports for the 18 and the 28 differ slightly optional Hard Shell provides surfaces for mounting
in size. lights, cameras etc.

Both the 18 and 28 are approved.

16 © Copyright 1970-2009 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080115002
 EXO Full-Face Mask Manual

KMACS-5
w/ No Comunications

SuperMask M-48 SuperMask M-48

w/ Scuba Pod w/ Rebreather pod
(Military only)
™ KMACS-5
marked w/ Communications

The SuperMask M-48 is an innovative new design The Kirby Morgan Air Control System-5
in a full-face mask. It provides the diver with all the (KMACS-5) is a lightweight, portable control box
comfort of a full-face mask with the convenience of for use in surface supplied air diving operations. The
changeable second stage regulators as well as the KMACS-5 controls the diver’s air supply, communi-
ability to use a snorkel without having to remove the cations and monitors the diver’s depth. It allows two
mask. divers clear push-to-talk (two wire) or round robin
(four wire) communications. The KMACS-5 is also
The mask is comprised of two major components, available without communications.
the mask frame and the interchangeable lower pod.
The removable lower pod is a feature unique to the The air supply can be either from a low-pressure
SuperMask full-face mask. When diving, the pod is compressor or high-pressure cylinders. The adjustable
easily removed and replaced on the mask, providing first stage regulator reduces the high-pressure air and
the diver the capability to buddy-breathe, snorkel, use supplies low pressure through the umbilical to the
an octopus or perform an “in water” gas switch. diver’s breathing system.

With the pod sealed to the mask, the flexible, silicone High pressure yokes permit U.S. standard scuba
pod cover allows the diver to quickly place the regula- cylinders to be used. Low-pressure air supply fittings
tor mouthpiece into the mouth or dive with it free of allow for a compressor to be used as the primary air
the mouth for communications. With the mouthpiece source.
in, the regulator may be used without the pod being
sealed to the mask. A complete pneumo system with dual reading gauges
(both US Standard and Metric) is provided for each
The mask may also be used surface supplied. We are diver’s air, as well as a shut-off/bleed system that uses
currently developing several different pod configura- two high-pressure feed lines which allows changing
tions for both open circuit and rebreather use. For of used cylinders without interruption of the diving
further information, see our web site at www.Kirby- operation. Optional shut off valves allow the isolation
Morgan.com. of each diver’s air supply.

The Communication Set is a multipurpose intercom-

munication system that provides reliable and clear
communications between a topside operator (tender)
and one or more surface-supported divers, recompres-
sion chambers, or other submersible systems.

© Copyright 1970-2009 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080115002 17