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Kirby Morgan SuperLite 27 User Manual

Kirby Morgan SuperLite 27
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Diving with compressed breathing gas is a hazardous activity. Even if you do everything
right there is always the danger that you may be killed or injured. No piece of diving
equipment can prevent the possibility that you may be killed or injured any time you
enter the water.
SuperLite
®
27
®
Helmet
Operations and Maintenance Manual
KMDSI Part # 100-027
Kirby Morgan Dive Systems, Inc.
1430 Jason Way
Santa Maria, CA 93455, USA
Telephone (805) 928-7772, FAX (805) 928-0342
E-Mail: KMDSI@KirbyMorgan.com, Web Site:www.KirbyMorgan.com
Manual prepared by Marine Marketing and Consulting, Dive Lab, Inc., and KMDSI.
NOTE: This manual is the most current for the SuperLite
®
27
®
Helmet. It is page dated January 2013. Future
changes will be shown on page III and the changed pages will carry the date of change. Previous manuals may not
reect these updates.
Document Number 130115001
Kirby Morgan, SuperLite
®
, BandMask, Band Mask, KMB, KMB-Band Mask, DSI, Diving Systems International, EXO, REX
®
,
SuperFlow
®
and DECA are all registered trademarks of Kirby Morgan Dive Systems, Inc. Use of these terms to describe products
that are not manufactured by KMDSI is illegal.
The two dimensional images (such as photographs and illustrations) of our products are © copyrighted and trademarks of Kirby
Morgan Dive Systems, Inc. The three dimensional forms of our products are trademark, trade design and trade dress protected.
© ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. This manual is made available for the express use of the owner of
this Kirby Morgan product. No part of this manual may be reproduced, stored in any retrieval system, or transmitted, or used in any
form or by any means, whether graphic, electronic, mechanical, photocopy, or otherwise by technology known or unknown, without
the prior written permission of Kirby Morgan Dive Systems, Inc.
The SuperLite
®
27
®
helmet is CE Approved and meets or exceeds all performance and testing require-
ments of all government and non-government testing agencies throughout the world. It is approved
for use on all commercial and military work underwater.
WARNING

Table of Contents

Questions and Answers:

Kirby Morgan SuperLite 27 Specifications

General IconGeneral
BrandKirby Morgan
ModelSuperLite 27
CategoryDiving Instrument
LanguageEnglish

Summary

Chapter 1 General Information KMDSI Products

1.1 Introduction

Provides manufacturer's advice on using the SuperLite® 27® helmet.

1.2 Full-Face Masks and Manifolds

Describes Kirby Morgan's full-face masks and their features.

1.3 Kirby Morgan Diving Helmets

Introduces Kirby Morgan's range of diving helmets and their features.

Chapter 2 Description & Operational Specifications

2.1 CR Marking

Explains the CR (Commercially Rated) marking established by Dive Lab.

2.2 CE Certification

Details the helmet's compliance with European CE standards and directives.

2.2.2 Notified Body

Identifies the notified body for CE certification as Eurofins-Modulo Uno S.p.A.

2.3 Product Specifications

Lists the technical specifications of the helmet, including materials and components.

2.4 Regulator Performance

Discusses the performance characteristics of SuperFlow® demand regulators.

2.5 Cage Code

Provides the KMDSI cage code for US government purchases.

2.6 Operational Specifications & Limitations

Outlines the helmet's operational capabilities and any usage restrictions.

2.7 Helmet Features

Details the innovative design and key features of the SuperLite® 27® helmet.

2.8 General Description

Provides an overview of the helmet's main components and construction.

2.8.1 Helmet Shell

Describes the construction and material of the helmet shell.

2.8.2 Gas Flow Systems

Explains how breathing gas flows through the helmet's internal systems.

2.8.3 Emergency Gas Supply System (EGS)

Details the importance and components of the Emergency Gas Supply System.

2.8.4 Helmet Attachment to the Diver

Explains how the helmet attaches securely to the diver's head.

2.8.5 Locking Sealed Pull Pins

Describes the function and servicing of the sealed pull pin locking system.

2.8.6 Sealing Arrangement

Details the neck dam's role in sealing the helmet to the diver's neck.

2.8.7 Reducing Carbon Dioxide

Explains how the oral nasal mask helps reduce CO2 buildup.

2.8.8 Communications

Describes the helmet's integrated communication system components.

2.8.9 Equalizing the Middle Ear

Explains the function of the nose block device for ear equalization.

2.8.10 Face Port or Viewing Lens

Details the face port, its material, and replacement procedures.

2.9 Accessories

Introduces optional accessories for the helmet.

2.9.1 Eye Protection for Welding

Describes the installation of welding lens and shield assemblies.

2.9.2 Hot Water Shroud

Discusses the hot water shroud for maintaining gas temperature in cold water.

2.9.3 Special Regulator Tools

Lists specialized tools for demand regulator adjustments and maintenance.

2.11 Use of Kirby Morgan Original Replacement Parts

Emphasizes the importance of using genuine KMDSI replacement parts.

Chapter 3 Operating Instructions

3.1 Introduction

Provides manufacturer's advice on how to use the SuperLite® 27® helmet.

3.2 Design Purpose

Explains that all Kirby Morgan helmets are designed for use with an umbilical.

3.3 First Use of Your Kirby Morgan Diving Helmet

Guides the user on initial inspection and handling of the new helmet.

3.4 Initial Adjustments to Your Kirby Morgan Helmet

Details necessary adjustments for a proper and comfortable fit.

3.4.1 Head Cushion

Explains how to adjust the head cushion for a proper fit.

3.4.2 Trimming the Neck dam

Provides instructions on trimming the neck dam for optimal fit.

3.4.3 Adjusting the Neck Pad

Describes how to adjust the neck pad for comfort and fit.

3.5 Pre Dress-In Procedure

Outlines essential pre-dive checks for ensuring operational readiness.

3.5.1 Pre-Dive Visual Inspection

Details the visual inspection steps for the helmet before diving.

3.6 Preparing the Helmet for Diving

Covers pre-dive preparation steps for the helmet.

3.6.1 Clean Face Port

Instructions on cleaning the face port safely.

3.6.2 Check Moving Parts

Verifies the smooth operation of all helmet's moving components.

3.6.3 Check Communications

Ensures the communication system is functioning correctly.

3.6.4 One Way Valve Check

Details the daily testing procedure for the one-way valve.

3.7 Emergency Gas System (EGS)

Explains the function and necessity of the EGS for diver safety.

Possible Emergency Gas Supply Cylinder & EGS Valve Configurations

Compares different configurations for the emergency gas supply system.

3.8 Setting Up to Dive

Provides instructions for connecting the helmet to the dive system.

3.8.1 Flushing Out the Umbilical

Details the procedure for flushing the umbilical before connection.

3.8.2 Connecting the Umbilical to the Helmet

Explains the proper method for connecting the umbilical to the helmet.

3.8.3 Opening the Breathing Gas Supply to the Helmet

Guides on how to safely turn on the breathing gas supply to the helmet.

3.8.4 Fogging Prevention

Offers advice on preventing face port fogging using approved solutions.

3.8.5 Donning the Helmet

Step-by-step instructions for putting on the helmet correctly.

3.8.6 Testing the Breathing System

Describes how to test the helmet's breathing system before diving.

3.8.7 Sealing Integrity Check

Details a test to ensure the helmet's seal is properly functioning.

Diving Procedures

Covers the sequence of actions for performing a dive safely.

3.9.1 Standing By to Dive

Describes the diver's actions while waiting to enter the water.

3.9.2 Attaching the Umbilical to the Harness

Explains how to properly secure the umbilical to the diver's harness.

3.9.3 Diver Dons Helmet

Refers back to previous section on donning the helmet.

3.9.4 Diver Check Gas Flow Systems

Diver checks breathing system operation before entering water.

3.9.5 Communications Check

Verifies the functioning of the communication system.

3.9.6 Diver Ready

Indicates the diver is prepared for water entry.

3.9.7 Water Entry and Descent

Procedures for entering the water and descending.

3.9.8 Adjust Regulator for Low Work Rates

How to adjust the regulator for low work rates and CO2 management.

Emergency Procedures

Covers critical steps to take in emergency situations during a dive.

3.10.1 Flooding

Procedures for clearing water from the helmet in case of flooding.

3.10.2 Inhalation Resistance

Steps to take if the diver experiences breathing difficulty.

3.10.3 Gas Flow Stops

Actions to take if the demand regulator stops delivering gas.

3.10.4 Demand Regulator Free Flow

How to handle or abort a dive if the demand regulator free flows.

Post Dive Procedures

Steps to follow after completing a dive to ensure equipment care.

3.11.1 Removing the Equipment

Steps for removing all equipment after the dive.

3.11.2 Removing the Helmet

Detailed procedure for safely removing the helmet.

3.11.3 Storage of the Helmet Between Dives

Guidance on proper storage of the helmet to maintain its condition.

Troubleshooting

4.1 General

General advice on troubleshooting common helmet issues.

4.2 Communication Malfunction

Lists common communication problems and their remedies.

4.3 One Way Valve Malfunction

Addresses issues related to the one-way valve's function.

4.4 Side Valve Malfunction

Troubleshooting steps for side valve issues, including defogger problems.

4.5 Water Leakage Into Helmet

Identifies causes and solutions for water entering the helmet.

4.6 Demand Regulator Malfunction

Lists potential problems with the demand regulator and their solutions.

4.7 Emergency Gas Supply Valve

Troubleshoots issues with the emergency gas supply valve.

Inspection and Maintenance

5.1 Routine Maintenance

Emphasizes the criticality of regular maintenance for reliability.

5.1.1 Daily Pre-Dive Maintenance A2.3

Daily checks to ensure the helmet is ready for diving.

5.1.2 Daily Post Dive Maintenance A2.6

Daily cleaning and inspection procedures after use.

5.1.3 Supervisors Equipment Checks A2.4 and A2.5

Checks conducted by supervisors to ensure equipment readiness.

5.2 Monthly Maintenance

Guidelines for monthly inspections to maintain serviceability.

5.3 Yearly Maintenance

Procedures for annual overhauls and detailed inspections.

General Preventative Maintenance

6.1 Introduction

Covers necessary preventative maintenance for the SuperLite® 27® helmet.

6.2 Required tools, Cleaning Agents, Lubrication

Lists tools, cleaning agents, and lubricants needed for maintenance.

6.2.1 Component and Parts Cleaning

Instructions for cleaning helmet components safely and effectively.

6.2.2 Component and Parts Lubrication

Details the types of lubricants and their application for helmet parts.

6.2.3 Teflon® Tape

Proper use of Teflon tape for sealing pipe thread fittings.

6.2.4 RTV Sealant

Recommendations for using RTV sealant for bonding and sealing.

6.2.5 Thread Locker

Specifies the recommended thread locker and its application.

General Cleaning & Inspection Procedures

General guidelines for cleaning and inspecting all helmet parts.

6.3.1 O-Ring Removal/Inspection/Cleaning and Lubrication

Procedures for handling O-rings, including removal, inspection, and cleaning.

6.3.2 General Cleaning Guidelines

Outlines general cleaning and sanitizing procedures for the helmet.

6.3.2.1 Soap Solution for General Cleaning and Leak Detector Use

Details the preparation and use of a soap solution for cleaning and leak detection.

6.3.2.2 Acidic Cleaning Solution and Procedures

Procedures for cleaning parts with visible corrosion using vinegar solution.

6.3.2.3 Germicidal Cleaning Solutions and Procedure

Provides approved germicidal solutions and procedure for sanitizing.

Daily Maintenance

Daily maintenance tasks to be performed after diving operations.

6.5 Monthly Maintenance (or between jobs)

Recommended monthly maintenance schedule for optimal helmet performance.

6.5.1 Locking Collar Assembly & Helmet Ring

Inspection of the locking collar and helmet ring for proper function.

6.5.2 Neck Dam Ring Assembly

Inspection of the neck dam ring assembly for wear and proper fit.

6.5.3 Head Cushion and Chin Cushion

Inspecting and replacing the head and chin cushion foam for comfort.

6.5.4 Communications Inspection

Visual inspection and testing of the communication system components.

6.5.5 Lubricate Nose Block O-Rings Tools Required

Lubrication procedure for nose block O-rings using specified tools.

6.5.6 Inspect the Exhaust Valve

Inspecting the exhaust valve and its housing for damage or wear.

Breathing System Maintenance and Repairs

7.1 Introduction

Covers maintenance and repair of all breathing system components.

7.2 Torque Values

Importance of tightening fasteners to correct torque specifications.

7.3 One Way Valve

Maintenance and repair procedures for the one-way valve assembly.

7.3.2 Reassembly of the One Way Valve

Step-by-step guide for reassembling the one-way valve after service.

7.4 Side Block Assembly

Details the maintenance and overhaul of the side block assembly.

7.4.1 General

General information on side block assembly maintenance and overhaul.

7.4.2 Side Block Assembly Removal

Procedures for removing the side block assembly from the helmet.

7.4.3 Separating the Side Block Assembly from the Helmet Shell

Steps to detach the side block from the helmet shell.

7.4.4 Side Block Assembly Replacement

Instructions for installing a new or serviced side block assembly.

7.5 Defogger Valve

Maintenance and repair procedures for the defogger valve.

7.5.1 Disassembly of the Defogger Valve

Steps for disassembling the defogger valve for service.

7.5.2 Cleaning and Lubricating

How to clean and lubricate the defogger valve components.

7.5.3 Reassembly of the Defogger Valve

Guide for reassembling the defogger valve after maintenance.

7.6 Emergency Valve Assembly

Maintenance and repair of the emergency valve assembly.

7.6.1 Disassembly of the Emergency Valve

Steps to disassemble the emergency valve for inspection.

7.6.2 Cleaning and Lubricating

Procedures for cleaning and lubricating the emergency valve.

7.6.3 Reassembly of Emergency Valve

Guide for reassembling the emergency valve after service.

7.7 Bent Tube Assembly

Maintenance and repair of the bent tube assembly.

7.7.1 General

General information on the bent tube assembly's function and maintenance.

7.7.2 Removal of the Bent Tube Assembly

Steps for removing the bent tube assembly from the helmet.

7.7.3 Inspection of Bent Tube Assembly

How to inspect the bent tube assembly for wear or damage.

7.7.4 Reinstallation of the Bent Tube Assembly

Instructions for properly reinstalling the bent tube assembly.

7.8 Demand Regulator SuperFlow® 350

Covers maintenance and adjustment of the SuperFlow® 350 demand regulator.

7.8.1 Demand Regulator Test for Correct Adjustment, Fully Assembled

Procedure for testing and adjusting the regulator before each dive.

7.8.2 Inspection of Regulator Body Interior

How to inspect the internal components of the regulator body.

7.8.3 SuperFlow® 350 Demand Regulator Bias Adjustment Servicing, Demand Regulator on the Helmet

Servicing the bias adjustment for the SuperFlow® 350 regulator while on the helmet.

7.8.4 Reassembly of the SuperFlow® 350 Regulator Adjustment System

Steps to reassemble the regulator adjustment system.

7.8.5 Demand Regulator Assembly Removal from Helmet

Procedure for removing the entire demand regulator assembly from the helmet.

7.8.6 Disassembly of the SuperFlow® 350 Demand Regulator

Detailed steps for disassembling the SuperFlow® 350 demand regulator.

7.8.7 Inspection of Demand Regulator Parts

Inspecting individual parts of the demand regulator for wear or damage.

7.8.8 Reassembly of the SuperFlow® 350 Demand Regulator

Guide for reassembling the SuperFlow® 350 demand regulator.

Overpressure Relief / Bleed Valve Overhaul Procedures

Procedures for overhauling the overpressure relief/bleed valve.

7.12.1 Overpressure Relief Valve

Explains the function of the relief/bleed valve for EGS regulators.

7.12.2 Overpressure Relief Valve Disassembly and Cleaning

Steps for disassembling and cleaning the overpressure relief valve.

7.12.3 Overpressure Relief Valve Reassembly

Guide for reassembling the overpressure relief valve after service.

7.12.4 Overpressure Relief Valve Lift Check/Setting

Procedure for checking and setting the relief valve's lift pressure.

Corrective Maintenance

8.1 General

Covers maintenance and repair of non-breathing system components.

8.2 Helmet Shell Inspection

How to inspect the helmet shell for damage like cracks or gouges.

8.3 Nose Block Assembly

Procedures for removing and replacing the nose block assembly.

8.3.1 Nose Block Assembly Removal

Steps for removing the nose block assembly from the helmet.

8.3.2 Nose Block Device Replacement

Instructions for installing a new nose block device.

8.4 Handle and Weights

Describes the handle and its use for mounting accessories.

8.4.1 Handle Removal Tools Required

Lists tools needed for removing the helmet handle.

8.4.2 Handle Replacement

Procedures for replacing the helmet handle.

8.4.3 Side Weight Removal

How to remove side weights from the helmet.

8.4.4 Weight Replacement

Instructions for installing new weights onto the helmet.

8.4.5 Diamond Weight Removal Tools Required

Tools needed to remove optional diamond weights.

8.4.6 Diamond Weight Replacement

Procedures for replacing optional diamond weights.

8.5 Face Port

Details the face port (viewing lens) and its importance.

8.5.1 General

General information about the face port and when to replace it.

8.5.2 Face Port and Nose Block Device Removal

Steps to remove the face port and nose block device.

8.5.3 Face Port and Nose Block Replacement

How to replace the face port and nose block device.

8.5.4 Special Note Regarding Ports

Important note regarding the interchangeability of face ports.

8.6 Neck Dam

Information on neck dam types and their installation.

8.6.1 Removal of the Neck Dam

Procedures for removing the neck dam assembly.

8.6.2 Neoprene Neck Dam Replacement

Instructions for replacing the standard neoprene neck dam.

8.6.3 Latex Neck Dam Replacement

Steps for installing the optional latex neck dam.

8.6.4 Trimming a Latex Neck Seal

How to trim a latex neck seal for a proper fit.

8.7 Neck Dam Pull Strap

Maintenance of the neck dam pull strap.

8.7.1 Neck Dam Pull Strap Removal

How to remove the neck dam pull strap.

8.7.2 Neck Dam Pull Strap Replacement

Steps to replace the neck dam pull strap.

8.8 Chin Strap

Procedures for removing and replacing the chin strap.

8.8.1 Chin Strap Removal

How to remove the chin strap.

8.8.2 Chin Strap Replacement

Steps for replacing the chin strap.

8.9 O-Ring Seal Replacement

Details how to replace the O-ring on the neck dam ring assembly.

8.10 Helmet Ring

Information on repairs for the helmet's metal ring.

8.10.1 Helmet Ring Repairs

Explains that helmet ring repairs require factory service.

8.11 Sealed Pull Pins

Information on servicing and replacing the helmet's sealed pull pins.

8.11.1 Removal of Sealed Pull Pins

Steps for removing the sealed pull pins.

8.11.2 Replacement of Sealed Pull Pins

Instructions for installing new sealed pull pins.

8.12 Swing Tongue Catch

Describes the swing tongue catch and its function.

8.12.1 Disassembly of the Swing Tongue Catch

Steps for disassembling the swing tongue catch assembly.

8.12.2 Reassembly of the Swing Tongue Catch

Instructions for reassembling the swing tongue catch.

8.13 Locking Collar

Details the function and removal of the locking collar.

8.13.1 Locking Collar Removal

Steps to remove the helmet's locking collar.

8.13.2 Locking Collar Disassembly

Procedures for disassembling the locking collar.

8.13.3 Locking Collar Reassembly

Instructions for reassembling the locking collar.

8.14 Head Cushion and Chin Cushion

Procedures for replacing head and chin cushion foam.

8.14.1 Head Cushion Foam

How to replace the head cushion foam for proper fit.

8.14.2 Chin Cushion Foam

How to replace the chin cushion foam.

8.15 Communications System

Information on the helmet's communications system.

8.15.1 General

Importance of the communications system for diver safety.

8.15.2 Earphone Inspection

How to inspect and service the helmet earphones.

8.15.3 Removal of Communications Assembly

Steps to remove the entire communications assembly.

8.15.4 Replacement of Communications Assembly

Procedures for replacing the communications assembly.

8.15.5 Microphone Replacement

How to replace the microphone component.

8.15.6 Earphone Replacement

How to replace individual earphones if needed.

8.15.7 Waterproof Connector

Information on the waterproof connector and its replacement.

8.15.7.1 Connector Removal

Steps to remove the waterproof connector.

8.15.7.2 Connector Replacement

Instructions for installing a new waterproof connector.

8.15.8 Terminal Connections in the Waterproof Connector

Details on connecting wires to the waterproof connector terminals.

8.15.9 Communications Posts

Procedures for servicing the communications posts.

8.15.9.1 Communications Post Removal

How to remove the communications posts.

8.15.9.2 Communications Post Replacement

Steps for replacing the communications posts.

Chapter 9.0 Accessories for the SuperLite® 27®

9.1 Introduction

Introduces KMDSI accessories for the SuperLite® 27®.

9.2 Hot Water Shroud

Explains the benefits and use of the hot water shroud.

9.2.1 Hot Water Shroud Installation Procedures

Step-by-step guide for installing the hot water shroud kit.

9.3 Low Pressure Inflator Hose

Information on the low pressure inflator hose.

9.3.1 Installation of the Low Pressure Inflator Hose

Procedures for installing the low pressure inflator hose.

9.4 Weld Lens Assembly

Details the weld lens assembly and its installation.

9.4.1 Weld Lens Assembly Installation

Instructions for installing the weld lens assembly.

9.5 Weld Shield Assembly

Information on the weld shield assembly.

9.5.1 Weld Shield Assembly Installation

Procedures for installing the weld shield assembly.

9.6 Use of Quick Disconnect

Explains the use of quick disconnects for bail-out systems.

Table of Equivalents

Appendix 1: Torque Specifications

Appendix A2 Maintenance and Inspection Procedures

A2.1 All SL and KM helmets (all models) Recommended Annual Maintenance Inspection and Overhaul

Procedures for annual maintenance and overhaul of SL and KM helmets.

A2.2 Monthly Maintenance

Guidelines for performing monthly maintenance on helmets.

A2.3 Daily Set-Up and Functional Checklist

Daily checklist for setting up and functionally checking the helmet.

A2.4 Supervisor’s Equipment Checks Prior to Entry

Checks conducted by supervisors before a diver enters the water.

A2.5 Supervisor’s Equipment Checks In-Water

Checks performed by supervisors while the diver is in the water.

A2.6 Post Dive Cleaning

Procedures for cleaning the helmet after a dive.

Appendix 3 Supply Pressure Requirements & Tables

Table 1 Work Rate Expressed as Respiratory Minute Volume (RMV)*

Relates work rates to RMV and equivalent land-based exercises.

Table 2 Compressor Supply Table SuperFlow® and SuperFlow® 350

Provides compressor supply pressure requirements for SuperFlow® regulators.

Appendix 3 Table 3 SuperFlow® 450 SS Balanced Regulator Low Pressure Compressor Table

Compressor supply table for SuperFlow® 450 SS balanced regulators.

Appendix 3 Table 4 SuperFlow® / SuperFlow® 350 Regulator High Pressure Regulated Source Supply Pressure Guidelines

Supply pressure guidelines for SuperFlow® regulators using high-pressure sources.

Appendix 4 Standard Kirby Morgan Surface Supply Pressure Formula - Old Method

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