Kirby Morgan 525-115 User manual

Kirby Morgan Dive Systems, Inc.®
1430 Jason Way Santa Maria, California 93455
Phone: [phone] Fax: [phone]
www.KirbyMorgan.com email: [email protected]
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© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 130611006
Part #525-115
Threaded Insert Test Block Kit
Part # Description Qty
430-075 Washer 1
530-045 Screw 1
550-115 Insert Test Block 1
-Threaded Insert Testing Procedure-
The following is Kirby Morgan’s approved method for testing the threaded inserts on the Kirby Morgan BandMask®s
and berglass helmets. Testing of the threaded inserts that accept the screws for the port retainer should be done at
least ONCE A YEAR. More often if frequent cutting and welding is performed (reference checklists for helmets
and Band Mask appendices on Kirby Morgan or Dive Lab websites).
When testing the threaded inserts on a helmet or mask, or when removing and replacing the port retainer, it is
crucial that the KMDSI recommended torque specs be followed when tightening the port retainer screws. Any
over torquing of a screw can result in serious damage to either the threaded insert or the surrounding berglass
or plastic in the port area. This can lead to loosening of the port retainer and in extreme instances to ooding of
the helmet. This testing procedure is designed to locate any inserts that have been damaged and need replacing.
Any replacement/repair of inserts and the surrounding berglass must be carried out by a certied technician that
has been factory trained specically in threaded insert repair/replacement. Any other repair/replacement is not
authorized by KMDSI and is a potential safety hazard. NOTE: Damaged KMB 28 frames or KMB 28 inserts are
not repairable/replaceable. This calls for a replacement frame.
One of the main causes of insert damage is the over torquing of the port retainer screws. This can be the nal
result of poor maintenance of the mask/helmet. Poor maintenance of the O-ring and O-ring groove on the mask/
helmet shell can lead to leaks around the port retainer. Overtightening of the retainer will not solve the leak and
will damage the berglass surrounding the inserts. Be sure that only a KMDSI P/N 510-260 O-ring is used for the
seal under the face port. This O-ring is a specially molded soft compound and was designed specically for this
application. Other O-rings, while being approximately the same size, will not perform correctly and can cause
leaks in the port area, mistakenly leading to overtightening, causing insert damage.
Denitions:
Port Retainer: The metal frame that holds the port in place against the sealing O-ring of the mask or helmet main
shell or frame.
Face Port: The transparent view port that the diver sees through.
Port Retainer Mount Screws: Screws that hold the port retainer to the frame or shell of the mask/helmet.

Kirby Morgan Dive Systems, Inc.®
1430 Jason Way Santa Maria, California 93455
Phone: [phone] Fax: [phone]
www.KirbyMorgan.com email: [email protected]
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 130611006
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Threaded Inserts: The stainless steel, female threaded, inserts that are bonded into the frame or shell of the mask/
helmet. These inserts receive the port retainer mounting screws. The port retainer mounting screws hold the port
retainer in place. The port retainer holds the face port in place on the mask/helmet frame or shell.
-Port Retainer Insert Testing-
Tools Required:
Adjustable Torque Screwdriver
Insert Test Block, Screw & Washer
Test Procedure:
1. Remove the port retainer, face port and O-ring according to the instructions in the mask/helmet manual.
2. Place the insert testing block over one of the threaded inserts and thread the testing block screw through the
washer and hole in the block and into the insert, tightening it hand tight (Fig. B).
3. Prepare to listen and observe the surrounding area as you tighten. Using the Adjustable torque screwdriver,
slowly tighten the test block screw to 14 inch pounds. While tightening, observe the insert and surround-
ing area. The insert should not move at all and there should not be any cracks in the surrounding berglass/
plastic. Also listen for cracking sounds as you tighten the screw. Any such sounds are an indication that the
berglass surrounding the insert has been stressed, damaged and should be repaired. KMB 28 frames would
require replacement.
4. With the screw tightened, check for cracks around the insert and/or edges of the face port area ( Fig. B). If
any are found, the area must be repaired, as this is a sign that the insert has been over tightened and has
damaged the berglass.
5. If, after checking all the inserts, they all pass the 14 inch pound test,
replace the O-ring, face port, and port retainer according to the manual
instructions and tighten all port retainer screws to 12 INCH POUNDS
with the adjustable
torque screwdriver.
6. Fig. A is an il-
lustration of the test-
ing block, screw and
washer. The block is
machined from alumi-
num stock.
Fig. B
Fig. B
Check for cracks around the out-
side of the face port area around
the inserts.
Insert Testing Block
Fig. A
P/N 530-045
Whisker Screw
P/N 430-075
Washer
Side View
P/N 550-115
Bottom View
P/N 550-115