Desco AIRHAT User manual

DESCO AIRHAT
CAT. NO. 61000
Overview
The DESCO Air Hat has been in production over 30 years, and has continually evolved to meet the
requirements of the Commercial Diving Industry. The Air Hat complies with all applicable industry and
government regulations including ADC, OSHA, U.S. Coast Guard, and CE. The Air Hat has a flow rate
capability in excess of that established by the U.S. Navy Divers Manual. Refer to the “Open Circuit System
Requirements” in the U.S. Navy Diving Manual for guidance in determining necessary airflow and overpressure
requirements for your application. Depth of the dive, hose diameter, air source, number of divers, and other
factors will effect the air delivery requirements. Therefore it is the responsibility of the contractor/diver to
determine the size of the air delivery system that will deliver a flow rate to adequately ventilate the Air Hat(s).
Policy Statement
When a new DESCO Air Hat leaves the factory it is as simple and safe as we can make it. It is designed to
operate safely and efficiently for many years without expensive or time-consuming maintenance. Its simplicity
however should not lull a diver into complacency. The Air Hat should receive good care and maintenance on a
regular basis to operate at peak efficiency. DESCO believes this design is the best balance of utility, durability,
and economy. DESCO Corporation cannot recommend, sanction, nor condone field modification of the Air Hat.
Modifying the Air Hat could result in unforeseen serious and life threatening consequences. Under no
circumstances should you remove wholly or in part any component, modifies components, or drill openings into
the Air Hat. Never circumvent the operation of any component of the Air Hat. Older Air Hats can be factory
retrofitted to bring them up to current standards. Double exhausts, double air inlet elbow (for bail-out system),
mounting blocks (for cameras and lights), or a penetrator elbow for a four wire communications plug can be
retrofitted, all or individually, by the factory.
If you have special requirements DESCO will attempt to accommodate your needs, provided they do not
compromise the safe operation of the Air Hat.
As DESCO strives to make diving equipment better, safer, and more user friendly we welcome comments and
suggestions from diving companies, regulatory agencies,and especially divers, whose safety is our ultimate
goal. Please feel free to contact us.
2007 DESCO Corporation
DESCO Corporation
240 N. Milwaukee Street
Milwaukee, Wisconsin 53202
Phone: [phone]
FAX: [phone]
E-Mail: [e-mail]
www.divedesco.com

Instructions for use and maintenance of the DESCO Air Hat.
Contents: Page
Section 1. Instructions for use of the Air Hat.
1. How the neck seal works. 1
2. Equipment Usable with the Air Hat. 2
3. Assembly of Neck Dam or Dry Suit Collar to Air Hat. 2
4. To Remove or Replace the Flat Neck Ring Gasket. 2
5. General Maintenance. 2
6. Disassembly and Reassembly. 3
7. To Adjust Headpiece Insert for Head Size. 3
8. To Remove or Replace the Flat Neck Ring Gasket. 3
9. How to Choose the Proper Size of Neck Dam. 3
10. Airflow rate. 4
11. How to Minimize Air Intake Noise.4
12. Non-Return and Bail-out Non-Return Valves. 4
13. Communications. 5
14. Mounting Blocks. 5
15. Welding Shield. 5
Section 2. Maintenance Schedule for the DESCO Air Hat 6
Section 3. Inspection of Air Hat Parts 7
Section 4. Helmet Disassembly 9
Air Hat Exploded View 11
Air Hat Parts List 12

DESCO AIR HAT DIVING HELMET
Section 1. Instructions for use of the Air Hat.
How the neck seal works:
To achieve a watertight seal at the neck, the Air Hat makes use of a brass neck ring insert, a large O-ring, rubber
shims (if necessary), and either a neoprene/foam neck dam, or the stretchable neck yoke of a dry suit. When
these components are properly assembled and the insert is pressed and locked into the neck ring of the Air Hat,
two separate sealing points are provided against entry of water. The seals are interdependent and both must be
properly installed to provide maximum watertight integrity.
A cross-sectional view of the neck ring of the Air Hat with the neck ring insert assembly inserted may be
visualized thus:
Seal No. 1 is provided by the neckdam (or dry suit yoke) pressed between the neck ring insert and the flat neck
ring gasket.The neck ring gasket is attached to the helmet neck ring with adhesive.
Seal No. 2 is provided by the large O-ring, which is pressed at its top against the shoulder of the neck ring, and
at its bottom against the lower surface of the channel in the brass neck ring insert. As the neck dam or dry suit
yoke age the material may compress necessitating the use of a shim to take up the additional space.
These two seals are different both in operation and effect. The flat neck ring gasket used in Seal No.1 is an
open-cell or sponge like material, which resists, but will not wholly prevent the passage of water. An open cell
material is used since it maintains its shape under pressure, at depth. So long as a positive air pressure is
maintained in the Air Hat no water will enter. Should the pressure in the Air Hat become negative, as when the
air is turned off and the diver inhales, a little water may enter. This can, however,readily be blown out through
the neck dam simply by closing the exhaust valve so that air is forced out through the neck dam. Seal No.2,
when adjusted properly, provides a completely watertight seal.
1

Equipment Usable with the Air Hat:
When attachment to a dry suit is not desired, the Air Hat can be used with the special DESCO neck dam, which
provides a seal at the diver’s neck. The Air Hat can also be mated to a conventional commercial collar dress by
means of the DESCO Neoprene Breastplate. This attaches to the dress in the same manner as a copper
commercial breastplate but incorporates a stretchable cylindrical collar, which is attached to the neck ring insert
so as to make a seal with the Air Hat. Similar use can be made of any dry suit, which comes equipped with such
a collar.
Assembly of Neck Dam or Dry Suit Collar to Air Hat:
To attach the DESCO neck dam to the Air Hat hold the brass neck ring insert with its smaller diameter up.
Bring the neck dam up through this ring with the taped edge outside and the nylon inside. Fold the top edge of
the neck dam at the point nearest your body out over the top of the insert ring so that the taped edge fits into the
channel. Holding this point against your body do the same with the opposite side of the neck dam. Then using
your free hand fold the rest of the top edge of the neck dam outward and over the channel. The large O-ring is
then placed in the insert ring channel on top of the neck dam material. If because of the thinness of this material
the O-ring fits too loosely one or more rubber shims can be placed in the channel on top or below the neck dam
material, beneath the O-ring. When properly fitted the O-ring should rest firmly against the neck dam material
without being stretched.
The collar of the Neoprene Breastplate or dry suit can be assembled to the neck ring insert in the same fashion,
except that with the thinner collar material it will nearly always be necessary to use one or more rubber shims in
order to properly fit the O-ring. To insure a completely watertight seal care must be taken to see that the large
O-ring is correctly fitted so its outer circumference contacts completely around the inside surface of the Air Hat
neck ring when it is clamped in place.
Both the large O-ring and the mating sealing surface in the Air Hat have been given a light coat of lubricant at
the factory. It will be found that keeping these parts clean and lubricated will ease installing the neck ring insert
assembly into the Air Hat, and will prolong the life of the O-ring. Use a lubricant suitable for rubber O-rings
(petroleum free).
To Remove or Replace the Flat Neck Ring Gasket:
This gasket, as supplied with the Air Hat, is attached to the neck ring using a pressure sensitive, wet-back,
adhesive, or “Glop”. It can be removed by peeling the gasket gently off the neck ring surface. A new gasket is
installed using the same type of adhesive. Care should be taken to see that the gasket’s outer edge is in contact
with and adhered to the wall of the neck ring at all points, otherwise the gaskets effectiveness as a seal is
reduced.
General Maintenance:
The basic materials and construction of the DESCO Air Hat shell are the same as those used in conventional
diving gear, and it should generally be cared for in the same manner. If used in salt water it should be washed
off with fresh water after use, and dried with a clean cloth. The Air Hat shell has a coating of tin-plating on the
copper and brass. After considerable use, and if desired, the Air Hat can be disassembled and the shell can be
retinned. Painted Air Hats are coated with DuPont Imron Polyurethane Enamel Paint. This is a high durability
Automotive and Boat coating. This finish should be treated in the same manner as a cars finish. The window is
Acrylic and care should be taken to prevent scratching the surface. Clean the window with standard glass
cleaner and a soft clean cloth. To remove very fine scratches and some stains use a specially formulated plastic
cleaner like Novus Plastic Polish No.2. This polish will also work on fine abrasions in the paint on the shell.
2

Disassembly and Reassembly:
The Air Hat can be completely disassembled using a screwdriver and wrench.The headpiece assembly is held
in the Air Hat by a single #10-32 hex nut in the center of the top band. To remove the headpiece assembly
unscrew the hex nut as pull the headpiece assembly out by the side opposite the air control valve. Backing out
or removing the communications binding posts will ease removal.
To replace the headpiece assembly insert the side at the air control valve first making sure it is clear of the
copper tube. Rock the assembly in till the top band is over the retaining stud, then check the assembly is aligned
left and right by gauging the distance between the snout/shell seam and the front end of the side pads. Replace
and tighten the hex nut.
To remove the copper air distribution tube, first loosen the air control valve-retaining nut so that the valve will
rotate freely. Secondly, completely unscrew the compression nuts at both ends of the copper tube and rotate the
valve body counter clockwise until the tube drops free. If the tube is undamaged it can be reused. If replacement
is necessary the compression ferrules will also have to be replaced. A set of stainless steel ferrules are used on
the valve end, and a set of brass ferrules on the elbow end. The small ferrule goes on first, then the larger one
with the tapers on both pointing towards the end of the tube.
WARNING: Teflon tape should never be used on any part of the Air Hat. The possibility exists for pieces
of Teflon tape to enter the air delivery system and cause a blockage.
Removal and installation of the other components of the Air Hat are obvious from inspection and require no
special instructions.
To Adjust Headpiece Insert for Head Size:
Size adjustments to the headpiece assembly are made with the assembly removed from the Air Hat. Loosen the
two brass screws on the upper edge of the back plate at the rear of the assembly. The proper fit is achieved by
changing the circumference of the headpiece assembly, by sliding the back band in or out. The headpiece
should fit snugly on the diver’s head, as the liner will compress somewhat under pressure. When the correct fit
is achieved tighten the two screws and reinstall in the Air Hat.
To Replace Foam Neoprene Pads on Headband Assembly:
All new Air Hats use an improved Headpiece Assembly utilizing Polypropylene band, which are impervious to
corrosion, unlike the brass bands of earlier Air Hats. The side pads are attached to the side band with pressure
sensitive tape making replacement simpler. The top pad is held in place by the top band passing through a slot
in the top. To change the pads remove the liner from the Air Hat. It is held in by a # 10 – 32 hex nut in the
center of the top pad. Peel off the old side pad and discard. Unbolt one side of the top band and slide off the old
top pad. Slide the new top pad into place and rebolt the top band. Clean any oil, grease, dirt, or old adhesive
from the area where the new side pads will go. You can use Denatured Alcohol or Lacquer Thinner to clean the
area. Make sure all the solvents are completely gone before using the Air Hat again. Peel the paper backing
from the new side pad and press firmly into place. As you reinstall the liner into the Air Hat make sure the top
pad is centered on the retaining stud hole in the top band. Watch the side pads as you install the liner so they do
not roll as you press the liner into place. Check the liner to make sure it is centered in the Air Hat and replace
and tighten the hex nut.
How to Choose the Proper Size of Neck Dam:
Neck Dams are available in sizes 12 through 15. The appropriate size is approximately two sizes smaller than
the diver’s regular collar size. Thus, a diver who wears a size 16 collar should use a size 14 Neck Dam. Custom
sized Neck Dams are available upon request.
3

Airflow rate:
The air train of the DESCO Air hat will deliver a minimum of 12cfm at 100psi. Each new and rebuilt Air hat is
tested at the factory to assure this flow rate. Factors such hose diameter, delivery pressure, and condition of the
Lambswool will effect this flow rate. The 6000 PSI Stainless Steel Hoke Valve (p/n 2112G6Y) is capable of
delivering in excess of 50 SCFM at 100 PSI. It will reach approximately 75% of its maximum flow at one turn
of the valve handle. DESCO recommends a minimum of 6CFM at 100 PSI to properly ventilate the Air Hat.
This figure is based on U.S. Navy Diving Manual recommendationsfor open circuit diving, and DESCO testing
of the Air Hat. For light work setting the Air Control Valve between ¾ and one turn will provide sufficient air
flow while reducing air flow noise. If the workload becomes more strenuous the flow rate should be increased.
How to Minimize Air Intake Noise:
The air train of the DESCO Air Hat will deliver a minimum of 12 cfm at 100 psi. Each new and rebuilt Air Hat
is tested at the factory to assure this flow rate.Factors such as hose diameter, delivery pressure, and condition of
the Lambswool will affect this flow rate. The 6000-PSI Stainless Steel Hoke Valve (Hoke P/N 2112G6Y) is
capable of delivering in excess of 50 SCFM at 100 PSI. It will reach approximately 75% of maximum flow at
one turn of the valve handle. DESCO recommends a minimum airflow deliveryof 6cfm to properly ventilate
the Air Hat. This figure is based upon U.S. Navy Diving manual recommendations for the Mark 12 helmet,
which has a higher interior volume than the Air Hat. For light work setting the Air Control Valve between ¾
and one turn will provide sufficient airflow while reducing airflow noise. If the workload becomes more
strenuous the flow rate should be increased.
The Polyethylene air distributor directs air across the inside surface of the window and helps to prevent fogging.
As delivered from the factory, the interior of this air distributor is tightly packed full of Lambs wool, which
greatly reduces air intake noise. If a new air distributor is installed be sure new Lambs wool is inserted and
packed. Lambs wool is a coarse fiber material that does not compress to the point where it would choke airflow.
THERE IS NO SUBSITIUTE FOR LAMBSWOOL. Cotton and other similar materials will compress to a point
where it can impede airflow. Never substitute another material in the air distributor. Lambs wool is available in
Drug Stores, and the health products aisle in most department and grocery stores. The Lambs wool will also act
as a filter in the incoming air.
Particulate matter coming down the air system can accumulate in the Lambs wool gradually reducing the
airflow capability. Periodically inspect the Lambs wool and replace if it is dirty, shows signs of compacting, or
is contaminated with oil. If the air distributor shows signs of a color change this may indicate oil contamination
and it should be checked.
IMPORTANT NOTE:
The flat neck ring gasket can take a set, which will reduce its effectiveness as a seal, if the neck ring insert
assembly is left clamped in the Air Hat while it is not in use. When the Air Hat is not going to be used the neck
ring insert assembly should be separated from the Air Hat.
Non-Return and Bail-out Non-Return Valves:
The Non-Return valve on the Air Hat is standard 9/16”- 18 Oxygen thread. The Bail-out Non-Return (marked
with a letter ”B”) is drilled to accept a SCUBA whip from a Bail-out Bottle. A dust cap is provided on the Bail-
out Non-Return to protect the threads when not in use. The dust cap will provide some sealing but a complete
airtight seal is not guaranteed. The integrity of the Non-returns can be tested by applying air pressure to the Air
Hat with the control valve fully closed, then removing the air supply hose, and applying a solution of
dishwashing detergent and water to the inlets. No air should leak back through the Non-Returns. If a leak is
found the Non-Return disk may require replacement. This test method can be used on all connections in the air
supply train.
4

Communications:
This new DESCO Air Hat comes equipped with a new speaker cup which incorporates the binding posts for
standard two-wire communications, and a port for the installation of a Marsh marine style plug assembly. This
port comes plugged from the factory unless the Air Hat is ordered with the two or four wire communications
plug option. The customer can install the plug assembly at a later time with parts DESCO can provide.
Instructions for connection of a four-wire communications equipped Air Hat to customer’s umbilical.
If your new Air Hat was ordered with the Four Wire Communications Plug assembly, the helmet is shipped
without any wiring connections made to the speaker. This allows the customer to match the connections in the
Air Hat to the umbilical communications line. The customer should check which wires are paired to the
microphone and to the speaker on the umbilical communications line. The wire pair going to the speaker should
be shortened so they can reach the binding post ends without any strain on them. Use the ring terminals
provided and connect the wires to the binding posts. Make sure the insulatorsare installed on the terminals as a
short circuit could result if bare terminals contact the helmet or each other. The microphone wires can be cut to
length according to the placement of the microphone, which is determined according to the customer’s location
preference.
Instructions for installing the four-wire communications assembly as a retrofit.
Remove the port plug and clean and inspect the threads. Check the fit of the bulkhead fitting by inserting the
fitting as far as possible by hand. It should easily engage the threads and turn in about 1/3 of the way. Remove
the fitting and mix a small amount of fast set two-part epoxy. Apply the epoxy to the threads on the fitting and
insert into the port. Tighten the fitting to approximately 3/4 of the length of the threads. Allow the epoxy to set
per the manufacturers recommendations. Slip the compression nut and ferrules provided onto the plug pigtail.
The nut and ferrules should be placed so as to leave enough of the plug out to connect to the umbilical without
straining. Approximate the final location of the plug in relation to the bulkhead fitting and strip off the excess
cable sheathing, leaving enough to pass through the bulkhead fitting into the helmet. Insert the cable through
the bulkhead fitting. If the cable resists passing through apply soapy water or silicone spray to the cable. Also,
the sheathing of the cable can be worked towards the bare wire ends of the cable to reduce the diameter to aid in
installation. Tighten the compression nut. Follow the connection instructions above to complete the installation.
Bench test the installation before placing the Air Hat “in service”.
Mounting Blocks:
Two mounting blocks have been added to the snout of the Air Hat. They are supplied with a 3/8”-16 x ½” Brass
hex bolt and a rubber washer. These mounts are useful for light and camera placements. Mounting ancillary
items on the Air Hat will change the natural balance of the helmet and should be taken into account.
Welding Shield:
A Welding Shield accessory is available for the Air Hat from DESCO (Cat. No.61001W/S). It features a
standard 4 ½”x 5 ¼” square lens, and the frame covers the entire faceplate. It comes with 2 stainless steel
screws, which should be used in lieu of the brass window screws.
5

Section 2. Maintenance Schedule for the DESCO Air Hat
The DESCO Air Hat is simple to maintain and will provide reliable service with normal care and maintenance.
The following schedule will keep your DESCO Air Hat in top working order.
Before each dive:
1. Inspect all seals for nicks and tears. Replace as necessary.
2. Inspect the window for nicks, cracks, and deep scratches, which may weaken it. Pay special attention to
the screw holes.
3. Check the window screws for damage and tightness.
4. Check the air control valve for smooth operation. There should be some resistance to opening and
closing of the valve to prevent accidental readjustment during the dive.
5. Inspect the clamp and lock mechanism for damage and adjustment. . There should be some resistance to
opening and closing of the clamps and locks to prevent accidental opening during the dive.
6. Inspect the shell of the helmet for damage. Pay special attention to fittings and joints
7. Inspect the insert ring for damage. Also inspect the O-Ring, shim (if installed), and neck dam (if
installed).
8. Test the air train. With air connected check the operation of the non-return valves and air train. Close the
air control valve to pressurize the air train. Turn off the compressed air supply to the helmet. After one
minute open the air control valve. Air should be heard escaping from the air distributor. If no air is heard
check all fittings for leakage, repair and retest.
Periodic Maintenance:
Due to the varying conditions that DESCO Air Hats will encounter it is not possible to suggest a fixed
interval for periodic maintenance. The compressor, umbilical, environment, and usage will all effect how
often the Air Hat will need comprehensive maintenance. Particular attention should be paid to these items
when doing periodic maintenance. DESCO recommends that the periodic maintenance be done fairly often.
It is not possible to over maintain a DESCO Air Hat.
1. Check Lambswool in the Air Diffuser for discoloration and/or particulate matter. Replace if any
contamination is observed. ONLY USE Lambswool in the Air Diffuser.Use of any other material in
the Air Diffuser is not recommended.
2. Check the threading on the non-return valves for wear, dirt, or damage. When reassembling the Air
Hat never use Teflon Tape in any part of theair train. Loose pieces of tape can clog the
Lambswool or air control valve and result in loss of airflow.
3. Check all items, which are not easily accessible during the pre dive inspections.
6

Section 3. Inspection of Air Hat Parts
Insert Ring Assembly
O-ring: Wash the O-ring in soap and warm water to remove all dirt and contaminates. Do a careful inspection
for cuts, nicks, or gouges. Look closely at the glue seam for any evidence of potential failure.
Neckdam: When examining for holes pay particular attention to the area where the Neckdam wraps back
around to pass under the O-ring. Slightly stretching the material aids in locating holes. Check for wear and
stretching at the lower end of the Neckdam where it contacts with the diver’s neck.
Shim: Where the shim has been removed intact from the insert ring check for deterioration of the shim material.
Insert Ring: Carefully inspect the insert ring for dents and nicks. Remove any burrs with very fine sandpaper.
Check the ring for evidence of damage, which may have put it out of round.
Window Assembly
Window: Check the window carefully for cracks, scratches, or chips along the edges. Inspect the windows
gasket-sealing surface for dirt or gasket material adhering to it.
Gasket:Wash the gasket and window with soap and warm water. Carefully inspect the gasket for cuts,
cracking, or nicks, and check that the gasket is not gotten hard or soft.
Window Screws: Check for excessive corrosion or if the screw is bent. Look for cracking where the threads
meet the head.
Exhaust Valve Assembly
Single Exhaust Valve: Generally look over the unit for contamination or damage. Inspect the solder joint
where the adjuster cap meets the cover. Look for corrosion or cracking. Check the movement of the plunger in
the cover assembly and the action of the spring. Work the adjuster cap as a check for the condition of the cap
threads. Excessive play in the operation of the adjuster would warrant further disassembly down to the
component parts. Check the condition of the four cover retaining screws.
Double Exhaust Valve: Generally look over the unit for contamination or damage. Inspect the solder joint
where the adjuster cap meets the top section. Look for corrosion or cracking. Check the movement of the
plunger in the topsection assembly and the action of the spring. Inspect the threads on the top section adjuster
assembly. Work the adjuster cap as a check for the condition of the cap threads. Excessive play in the operation
of the adjuster would warrant further disassembly down to the component parts. Check the condition of the
plunger in the top section and the flapper guard in the mid section. Look for signs that the flapper valve(s) may
be sticking to them.
O-ring: Wash the O-ring on soap and warm water. Carefully inspect for cuts and nicks.
Flapper Valve(s): Check for wear and cracking in the material. Look for signs of physical deterioration of the
material such as hardening or softening. Look for signs that the flapper valve may be sticking to the plunger or
flapper guard.
Body Sections: Look for signs of damage or corrosion. Look for plating flaking or cracking. Check the flapper
valve sealing surface on the mid body for wear or damage. Check the threads in the mid body for dirt or
corrosion.
7

Clamp and Lock Assembly
Clamps: Inspect the clamps for corrosion, bends and cracks. Inspect the clamp holes for cracks and wear.
Locks: Inspect the locks for cracks at the solder joint. Look for bending or twisting in the tab. Check the hole
for cracking or wear.
Bolts & Nuts: Inspect the bolts for corrosion, wear, and bending. Look at the nuts for rounding off and thread
corrosion or wear. Try threading the nuts and bolts together to test the threads and the nylon locks on the nuts. If
the nuts will not self-lock they should be replaced. If the nylon washers appear to be flattened out replace them.
Binding Post Assemblies and Communications
Binding Posts: Check the solder joint for cracking. Test the clamp nut for operation. Check for bending. Older
binding posts were drilled for inserting the communications wire. If the binding post has this hole look for
cracking of the post next to the hole.
Bushings: Check the bushing for cracks of excessive compression.
Nuts:Check for rounding off and the general condition of the threads.
Speaker:Check the speaker for operation using a sound source. Inspect the speaker, wire and terminals for
wear, corrosion, or damage.
Speaker Cup: Check for wear and damage.
Headpiece Assembly
Band Assembly: Inspect for corrosion, missing parts, or loose hardware. Check for wear and cracking.
Insert: Check for wear and excessive hardening of the pads. Check the screw fasteners to make sure they are
still firmly attached to the pad.
Top & Side Pads: Inspect for wear, compression, or damage. Check that they are still firmly attached to the
band.
Air Train Assembly
Non-Return Valve(s): Inspect the body parts for corrosion, wear, or damage. Check the threads for condition.
Check for damage to the valve seat. Look for loose plating or corrosion. Check the spring for loss of strength or
corrosion.
Inside Elbow: Inspect the elbow for corrosion, wear, or damage.
Tube Inspect for corrosion, wear, or damage. Look for corrosion at the tube ends and on the ferrules where it
can interfere with the seals.
Air Control Valve Inspect for corrosion, wear, or damage. Look inside the valve openings for signs of foreign
material or contaminates. If the valve operation seemed loose before disassembly check the valve packing.
Check the valve stem for bending.
Air Diffuser Inspect for contamination or damage. Carefully remove the Lambswool into a plastic bag. Inspect
the Lambswool for contaminates and foreign material. Check the opening in the body for excessive wear. Look
at the body for oil or contaminate saturation.
8

Section 4. Helmet Disassembly
1. Before doing any disassembly inspect the general condition of the helmet. Look for signs of wear, corrosion
and/or damage.
a. Dents, deep scratches, or gouges in the helmet shell
b. Scratches, chips, or hazing in the Acrylic window.
c. Mechanical operation of the air control valve, exhaust valve, clamps and locks.
d. Dents, nicks, or gouges in the insert ring.
e. Holes in the neck dam (if installed).
f. Cuts or gouges in the insert ring O-ring.
g. Corrosion on any exposed solder joints.
h. Corrosion to nuts, bolts, and screws.
2. Disassemble the helmet keeping the parts grouped together as they are removed. During the detailed
inspection having the related parts together will aid in diagnosing problems. Some parts are best examined as
they are removed from the helmet. Sub assemblies will be individually examined after the helmet is
disassembled.
3. The disassembly sequence is as follows:
Insert Ring Assembly (with Neckdam installed):
a. Remove the assembly from the helmet.
b. Remove the O-ring from the insert ring.
c. Remove the Neckdam from the insert ring.
d. If the insert ring is fitted with a shim, remove it. On helmets where the shim has been in use for a
long time it may have adhered to the insert ring. It will be necessary to destroy the shim to
remove it. Carefully scrape the shim off of the insert ring. The insert ring can be cleaned with
Lacquer thinner and very fine steel wool to remove the residual shim material.
Window Assembly
a. Remove the six window screws from the front window. Take note of the force required to remove
them. The need for excessive force may indicate a damaged screw or significant corrosion in the
threads. Corrosion will be visually obvious on the screw threads. Check for any bent screws.
b. Remove the window and gasket from the helmet. The gasket may stick to the helmet frame, or
the window, or both. If necessary you may use a thin blade screwdriver or putty knife to release
the gasket being careful not to damage any of the parts.
Exhaust Valve Assembly (Double Exhaust):
a. Remove the two 6-32 screws closest to the helmet and pull the exhaust valve off of the base.
b. Remove the O-ring and flapper valve.
c. Remove the flapper screw and nut.
Exhaust Valve Assembly (Single Exhaust):
a. Remove the four 6-32 screws in the cover assembly.
b. Remove the flapper valve.
c. Remove the flapper screw and nut.
Clamp and Lock Assemblies:
a. Unbolt each clamp and lock assembly keeping the related parts together.
9

Binding Posts and Communications:
Old Style Installation:
a. Remove the speaker by first unscrewing the lock screw from the speaker ring. Pull the speaker
and cup from the ring. Detach the wires from the binding posts. Remove the post retaining nuts and
unscrew the binding posts. Remove the bushings from the block.
New Style Installation:
a.Remove the speaker from the side cup. It is held in place with two sided foam tape. Detach the wires
from the binding posts. Remove the post retaining nuts and unscrew the binding posts. Remove the
bushings from the block.
Headpiece Assembly:
a. Remove retaining nut in the center top of the helmet.
b. The side and top pads may be adhered to the shell. Slide a screwdriver or putty knife along the
shell and gently pry the pads loose. You may have to pry in several locations to keep from tearing
the pads.
c. The liner is easiest to remove by pulling the side by the binding post block in and up to clear the
block then hooking the assembly around from under the air train assembly.
Air Train Assembly:
a. Remove the Non-Return Valve/s from the helmet.
b. Remove the Air Control Valve Handle.
c. Loosen the valve-retaining nut.
d. Loosen the compression nuts on the copper tube and remove the tube.
e. Remove the valve-retaining stem adapter, valve retaining nut, brass and lead washers, and then
the valve. Use caution when removing the valve so as not to lose the compression ring off of the
valve stem. A piece of tape on the valve stem before the valve is removed will prevent loss.
f. Unscrew the Air Diffuser from the valve body.
g. The inside elbow can be removed if needed. It is secured using 10-minute two-part epoxy. Use
two adjustable wrenches, one on theflats of the elbow and one to turn the first wrench. Use
extreme caution to avoid damaging the threads or bending the elbow.
Video Block Assembly:
a. Unscrew the two 3/8” bolts from their blocks.
10

11

1-3 NECK RING INSERT ASSEMBLY 61050
1. NECK SEAL O-RING 61054
2. NECK RING INSERT 61051
3. NECK DAM 61052
4. SHIM 61053
5-7 WINDOW ASSEMBLY 61075
5. WINDOW 61076
6. WINDOW RETAINING SCREWS 61078
7. WINDOW GASKET 61077
8-18 AIR INTAKE ASSEMBLY 61125
8. COPPER TUBE 61127
9. INSIDE ELBOW 61126
10 AIR DISTRIBUTOR 61135
11. LAMBSWOOL
12. CONTROL VALVE 61128
13. VALVE HANDLE NUT 61134
14. VALVE HANDLE (NEW STYLE) 61133N
15. VALVE STEM ADAPTER 61132
16. VALVE RETAINING NUT 61131
17. BRASS WASHER 61130
18. LEAD WASHER 61129
19-27 POT & NECK RING ASSEMBLY 61025
19. POT & NECKRING 61026
20. NECK RING CLAMP (RIGHT) 61034
21. NECK RING CLAMP (LEFT) 61035
22. CLAMP SCREW 61030
23. CLAMP & LOCK WASHER 61031
24. CLAMP & LOCK NUT 61032
25. LOCK 61038
26. LOCK RETAINING SCREW 61037
27. NECK RING GASKET 61036
28-31 NON-RETURN VALVE ASS’Y 59091
28. BODY 53029
29. SPRING 57029
30. PLATE 52030
31. ADAPTER 53079
31. ADAPTER (BAILOUT) 53079B
32-44 DOUBLE EXHAUST ASSEMBLY 60231
32. LOCKNUT 53025
33. SCREW 53037
34. FLAPPER 56026
35. O-RING 60234
36. FLAPPER GUARD 60238
37. STAR WASHER 60237
38. SET SCREW 6-32 60235
39. CENTER SECTION 60233
40. PLUNGER 53024
41. SPRING 57029
42. TOP SECTION 60236
43. KNURLED CAP 53028
44. NUT 54016
12
45-55 HEAD PIECE ASSEMBLY 61100
45. TOP BAND 61103
46. HEAD BAND 61101
47. BACK PLATE 61104
48. 3/8” BRASS SCREW 61108
49. BRASS FLAT WASHER 61109
50. BRASS NUT 61110
51. TOP PAD 61113
52. SIDE PAD 61112
53. 7/16” BRASS SCREW 61114
54. INSERT 61106
55. SCREW 61107
56-59 COMMUNICATIONS 61200
56. BINDING POST (COMPLETE) 61224
57. SPEAKER WITH CLIPS 61205
58. FOAM SPEAKER COVER 61226
59. ¼” NPT PIPE PLUG 61227
60-68 SINGLE EXHAUST ASSEMBLY 59112T
60. EXHAUST BASE 51025
61. SCREW 53037
62. FLAPPER 53026
63. PLUNGER 53024
64. SPRING 27009
65. COVER 52090
66. SCREW 54025
67. CAP 53028
68. NUT 54058
69-71 VIDEO/LIGHT MOUNTS 61115
69. VIDEO/LIGHT BLOCK 61115
70. VIDEO/LIGHT BLOCK BOLT 61116
71. VIDEO/LIGHT BLOCK WASHER 61117
NOT SHOWN ON EXPLODED VIEW
These parts are for older DESCO Air Hats. The old style
communications used a binding post block. The binding
posts were larger. The transceiver was mounted above the
exhaust port in a plastic cup held by a brass ring. Two sizes
of speaker were offered but the larger may not fit on very
old Air Hats due to the speaker ring location. Parts with *
indicate parts for the four wire retrofit offered for older Air
Hats.
COMMUNICATIONS
RETAINING SCREW 54009
BINDING POST (COMPLETE) 61203
SPEAKER WITH CLIPS 61204
TELEPHONE CUP 61209
*4 WIRE COMM ELBOW 61214
*BULKHEAD FITTING 61215
*4 WIRE PIGTAIL 61216
MISCELLANEOUS
VALVE HANDLE (OLD STYLE) 61133