Kirby Morgan SuperLite 27 User manual

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 [phone], FAX [phone]
E-Mail: [e-mail], 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 May 2008. Future changes will
be shown on page III and the changed pages will carry the date of change. Previous manuals may not reflect these
updates.
™
Document Number 080528001
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.
© Copyright 1970-2007 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. Only Kirby Morgan masks and helmets
have achieved the CR (Commercial Rated) mark, the highest United States of America rating.
WARNING

SuperLite 27
II © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001
WARRANTY INFORMATION
Kirby Morgan Dive Systems, Inc. warrants every new mask, helmet, or KMAC Air Control System to be
free from defects in workmanship for a period of ninety (90) days from date of purchase. This warranty
coversallmetal,fiberglass,andplasticparts.ThiswarrantydoesNOT cover rubberparts,communications
components, or headliners. In addition, due to the electrolytic nature of underwater cutting and welding,
chrome plating cannot be warranted when the diver engages in these activities.
Should any part become defective, contact the nearest authorized KMDSI dealer. If there is no dealer in
your area, contact KMDSI directly at [phone]. You must have a return authorization from KMDSI
prior to the return of any item, Upon approval from KMDSI, return the defective part, freight prepaid, to
the KMDSI plant. The part will be repaired or replaced at no charge as deemed necessary by KMDSI.
This warranty becomes null and void if:
1) The product is not registered with KMDSI within ten (10) days of purchase.
2) The product has not been properly serviced and/or maintained according to the appropri-
ate KMDSI manual. In addition, the user is responsible to ensure that all product updates
as recommended by KMDSI have been performed.
3) Unauthorized modifications have been made to the product.
4) The product has been abused or subjected to conditions which are unusual or exceed the
product’s intended service.
NOTE: Be sure to complete the enclosed warranty card and return it to KMDSI immediately. No war-
ranty claims will be honored without a satisfactorily completed warranty card on file at KMDSI.

SuperLite 27
III
© Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001
It is the responsibility of the owner of this product to register their ownership with Kirby Morgan Dive
Systems, Inc., by sending the warranty card provided. This card is to establish registration for any necessary
warranty work and provides a means of communication that allows KMDSI to contact the user regarding this
product. The user must notify KMDSI of any change of address by the user or sale of the product.
All changes or revisions to this manual must be recorded in this document to ensure that the manual
is up to date.
RECORD OF CHANGES
Change Number Date Description of Change Page Number
1 05/28/2008 Reworded: 2.1 Product Specifications, 2.4 Operational Specifi-
cations &
Limitations, Warning bottom left on page 23
Added: 2.2.1 SuperFlow® and SuperFlow® 350 Demand Regu-
lators, 2.2.2 SuperFlow® 450 Performance, Appendix A2, 3
and 4.
Moved: 2.3 Cage Code to page 23
Removed: Tables 1 and 2 from chapter 2
22-23, 146-153

SuperLite 27
IV © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001
Diving with compressed breathing gas is a hazardous activity. Even if you do everything
right there is always the potential for serious injury or death. No one piece of diving
equipment can prevent the possibility that you may be injured or killed any time you
enter the water.We do not herein make any effort to teach the principles of diving.The
information in this manual is intended for users of Kirby Morgan helmets and persons
that maintain or service Kirby Morgan helmets.
WARNING

SuperLite 27
V
© Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001
Contents
Definition of Signal Words Used in this Manual X
Chapter 1.0 - General Information KMDSI Products 15
1.1 Introduction 15
1.2 The Kirby Morgan Diving Helmets, Masks & Air Control System 16
Chapter 2 - Description & Operational Specifications - SuperLite-27 22
2.1 Product Specifications 22
2.2 Regulator Performance 22
2.3 Cage Code 22
2.4 Operational Specifications & Limitations 23
2.5 Helmet Features 25
2.6 General Description 28
2.6.1 Helmet Shell 28
2.6.2 Gas Flow Systems 28
2.6.3 Emergency Gas Supply System (EGS) 30
2.6.4 Helmet Attachment to the Diver 31
2.6.5 Locking Sealed Pull Pins 31
2.6.6 Sealing Arrangement 32
2.6.7 Reducing Carbon Dioxide 32
2.6.8 Communications 32
2.6.9 Equalizing the Middle Ear 32
2.6.10 Face Port or Viewing Lens 32
2.7 Accessories 33
2.7.1 Eye Protection for Welding 33
2.7.2 Hot Water Shroud 33
2.7.3 Helmet Carrying Bag 34
2.7.4 Special Regulator Tools 34
Chapter 3.0 Operating Instructions 35
3.1 Introduction 35
3.2 Design Purpose 35
3.3 First Use of Your Kirby Morgan Diving Helmet 37
3.4 Initial Adjustments to Your SuperLite 27 37
3.4.1 Head Cushion 37
3.4.2 Trimming the Neck dam 37
3.4.3 Adjusting the Neck Pad 38
3.5 Pre Dress-In Procedure 39
3.5.1 Pre-Dive Visual Inspection 39
3.6 Preparing the Helmet for Diving 40
3.6.1 Clean Face Port 40
3.6.2 Check Moving Parts 40
3.6.3 Check Communications 40
3.6.4 One Way Valve Check 40
3.7 Emergency Gas System (EGS) 40
3.8 Setting Up to Dive 45
3.8.1 Flushing Out the Umbilical 45
3.8.2 Connecting the Umbilical to the Helmet 45
3.8.3 Opening the Breathing Gas Supply to the Helmet 46
3.8.4 Fogging Prevention 46
3.8.5 Donning the Helmet 46
3.8.6 Testing the Breathing System 49
3.8.7 Sealing Integrity Check 49

SuperLite 27
VI © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001
3.9 Diving Procedures 50
3.9.1 Standing By to Dive 50
3.9.2 Attaching the Umbilical to the Harness 50
3.9.3 Diver Dons Helmet 50
3.9.4 Diver Check Gas Flow Systems 50
3.9.5 Communications Check 50
3.9.6 Diver Ready 50
3.9.7 Water Entry and Descent 50
3.9.8 Adjust Regulator for Low Work Rates 50
3.10 Emergency Procedures 52
3.10.1 Flooding 52
3.10.2 Inhalation Resistance 52
3.10.3 Gas Flow Stops 52
3.10.4 Demand Regulator Free Flow 52
3.11 Post Dive Procedures 53
3.11.1 Removing the Equipment 53
3.11.2 Removing the Helmet 53
3.11.3 Storage of the Helmet Between Dives 53
Chapter 4.0 Troubleshooting 54
4.1 General 54
4.2 Communication Malfunction 54
4.3 One Way Valve Malfunction 55
4.4 Side Block Malfunction 55
4.5 Water Leakage Into Helmet 55
4.6 Demand Regulator Malfunction 56
4.7 Emergency Gas Supply Valve 56
Chapter 5.0 Inspection 57
5.1 Daily Maintenance 57
5.2 Monthly Maintenance 57
5.3 Maintenance to be Performed Every Six Months 57
5.4 Yearly Maintenance 57
Chapter 6.0 General Preventative Maintenance 58
6.1 Introduction 58
6.2 Required tools, Cleaning Agents, Lubrication 58
6.2.1 Component and Parts Cleaning 59
6.2.2 Component and Parts Lubrication 59
6.2.3 Teflon Tape 60
6.2.4 RTV Sealant 60
6.2.5 Thread Locker 61
6.3 General Cleaning & Inspection Procedures 62
6.3.1 O-Ring Removal/Inspection/Cleaning and Lubrication 63
O-Ring Removal: 63
O-Ring Inspection: 63
O-Ring Reuse: 63
6.3.2 General Cleaning Guidelines 63
6.3.2.1 Soap Solution for General Cleaning and Leak Detector Use 63
6.3.2.2 Acidic Cleaning Solution and Procedures 63
6.3.2.3 Germicidal Cleaning Solutions and Procedure 63
6.4 Daily Maintenance 65
6.5 Monthly Maintenance (or between jobs) 66

SuperLite 27
VII
© Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001
6.5.1 Locking Collar Assembly & Helmet Ring 66
6.5.2 Neck Dam Ring Assembly 66
6.5.3 Head Cushion and Chin Cushion 67
6.5.4 Communications Inspection 67
6.5.5 Lubricate Nose Block O-Rings 67
6.5.6 Inspect the Exhaust Valve 67
Chapter 7.0 Breathing System Maintenance and Repairs 69
7.1 Introduction 69
7.2 Torque Values 69
7.3 One Way Valve 69
7.3.1 Disassembly Of The One Way Valve 69
7.3.2 Reassembly of the One Way Valve 70
7.4 Side Block Assembly 72
7.4.1 General 72
7.4.2 Side Block Assembly Removal 72
7.4.3 Separating the Side Block Assembly from the Helmet Shell 72
7.4.4 Side Block Assembly Replacement 74
7.5 Defogger Valve 76
7.5.1 Disassembly of the Defogger Valve 76
7.5.2 Cleaning and Lubricating 76
7.5.3 Reassembly of the Defogger Valve 77
7.6 Emergency Valve Assembly 78
7.6.1 Disassembly of the Emergency Valve 78
7.6.2 Cleaning and Lubricating 78
7.6.3 Reassembly of Emergency Valve 79
7.7 Bent Tube Assembly 81
7.7.1 General 81
7.7.2 Removal of the Bent Tube Assembly 81
7.7.3 Inspection of Bent Tube Assembly 81
7.7.4 Reinstallation of the Bent Tube Assembly 82
7.8 Demand Regulator SuperFlow 350 82
7.8.1 Demand Regulator Test for Correct Adjustment, Fully Assembled 83
7.8.2 Inspection of Regulator Body Interior 83
7.8.3 Demand Regulator Bias Adj. Servicing, Demand Regulator on Helmet 84
7.8.4 Reassembly of Adjustment System 85
7.8.5 Demand Regulator Assembly Removal from Helmet 85
7.8.6 Disassembly of the SuperFlow 350 Demand Regulator 86
7.8.7 Inspection of Demand Regulator Parts 88
7.8.8 Reassembly of the SuperFlow 350 Demand Regulator 89
7.8.9 Tuning the SuperFlow 350 Regulator 93
7.8.10 Regulator Steady Flows When Pressured Up: Special Tools Used 94
7.8.11 Regulator has Low or No Flow When Pressurized 96
7.8.12 Unexplained Demand Regulator Free Flow 96
7.9 Oral/Nasal 97
7.9.1 Oral/Nasal Removal 97
7.9.2 Inspection of Oral/Nasal 97
7.9.3 Oral/Nasal Replacement 97
7.10 Tri-Valve Exhaust 98
7.10.1 Tri-Valve™ Assembly Removal 98
7.10.2 Tri-Valve™ Exhaust Valve & Regulator Exhaust Valve Replacement 99
7.10.2.1 Tri-Valve™ Exhaust Valve Replacement 99
7.10.2.2 Regulator Exhaust Valve Replacement 100
7.10.3 Tri-Valve™ Assembly Installation 101
7.11 Main Exhaust Assembly Water Dump 102

SuperLite 27
VIII © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001
7.11.1 Water Dump Valve Removal 103
7.11.2 Water Dump Valve Replacement 103
7.11.3 Purge Valve Body Removal and Replacement 103
7.11.4 Purge Valve Body Installation 103
7.11.5 Water Dump Valve Body Removal 104
7.11.6 Water Dump Valve Body Remounting 104
7.12 Overpressure Relief / Bleed Valve Overhaul Procedures 105
7.12.1 Overpressure Relief Valve 105
7.12.2 Overpressure Relief Valve Disassembly and Cleaning 105
7.12.3 Overpressure Relief Valve Reassembly 106
7.12.4 Overpressure Relief Valve Lift Check/Setting 106
Chapter 8 Corrective Maintenance 108
8.1 General 108
8.2 Helmet Shell Inspection 108
8.3 Nose Block Assembly 109
8.3.1 Nose Block Assembly Removal 109
8.3.2 Nose Block Device Replacement 109
8.4 Handle and Weights 110
8.4.1 Handle Removal 110
8.4.2 Handle Replacement 110
8.4.3 Side Weight Removal 111
8.4.4 Weight Replacement 112
8.4.5 Diamond Weight Removal 112
8.4.6 Diamond Weight Replacement 112
8.5 Face Port 113
8.5.1 General 113
8.5.2 Face Port and Nose Block Device Removal 113
8.5.3 Face Port and Nose Block Replacement 114
8.5.4 Special Note Regarding Ports 116
8.6 Neck Dam 117
8.6.1 Removal of the Neck Dam 117
8.6.2 Neoprene Neck Dam Replacement 117
8.6.3 Latex Neck Dam Replacement 120
8.6.4 Trimming a Latex Neck Seal 121
8.7 Neck Dam Pull Strap 122
8.7.1 Neck Dam Pull Strap Removal 122
8.7.2 Neck Dam Pull Strap Replacement 122
8.8 Chin Strap 122
8.8.1 Chin Strap Removal 122
8.8.2 Chin Strap Replacement 122
8.9 O-Ring Seal Replacement 123
8.10 Helmet Ring 124
8.10.1 Helmet Ring Repairs 124
8.11 Sealed Pull Pins 124
8.11.1 Removal of Sealed Pull Pins 124
8.11.2 Replacement of Sealed Pull Pins 124
8.12 Swing Tongue Catch 125
8.12.1 Disassembly of the Swing Tongue Catch 125
8.12.2 Reassembly of the Swing Tongue Catch 126
8.13 Locking Collar 127
8.13.1 Locking Collar Removal 127
8.13.2 Locking Collar Disassembly 128
8.13.3 Locking Collar Reassembly 129
8.14 Head Cushion and Chin Cushion 130

SuperLite 27
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© Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001
8.14.1 Head Cushion Foam 130
8.14.2 Chin Cushion Foam 130
8.15 Communications System 131
8.15.1 General 131
8.15.2 Earphone Inspection 131
8.15.3 Removal of Communications Assembly 132
8.15.4 Replacement of Communications Assembly 132
8.15.5 Microphone Replacement 132
8.15.6 Earphone Replacement 133
8.15.7 Waterproof Connector 134
8.15.8.1 Connector Removal 134
8.15.8.2 Connector Replacement 134
8.15.9 Communications Posts 134
8.15.9.1 Communications Post Removal 134
8.15.9.2 Communications Post Replacement 135
Chapter 9.0 Accessories for the SuperLite 27 136
9.1 Introduction 136
9.2 Hot Water Shroud 136
9.2.1 Hot Water Shroud Installation Procedures 136
9.3 Low Pressure Inflator Hose 139
9.3.1 Installation of the Low Pressure Inflator Hose 139
9.4 Weld Lens Assembly 140
9.4.1 Weld Lens Assembly Installation 140
9.5 Weld Shield Assembly 141
9.5.1 Weld Shield Assembly Installation 141
9.6 Use of Quick Disconnect 141
Table of Equivalents 157
Appendix 1: Torque Specifications 158
Note on Torque Specifications 159
Appendix A2 - Maintenance and Inspection Procedures 160
Appendix 3 - Pressure Tables 148
Appendix 4 - Standard KMDSI Surface Supply Pressure Formula - Old Method 153

SuperLite 27
X© Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001
DANGER
CAUTION
For your protection, pay particular attention to items identified by signal words in this manual. These terms are identified
as, CAUTION, WARNING AND DANGER. It is especially important for you to read and understand these sections.
This word indicates an imminently hazardous situation, which if not avoided, could re-
sult in death or serious injury.
This word indicates a potentially hazardous situation, which, if not avoided, could result
in death or serious injury.
This word indicates a potentially hazardous situation, which if not avoided, may result in
minor or moderate injury. It may also be used to alert against unsafe practices.
If English is not your native language and you have any difficulty understanding the language of any warnings as they
appear in the manual, please have them translated.
Este é um aviso importante. Queira mandá-lo traduzir.
Este es un aviso importante. Sirvase mandario traducir.
Quest è un avviso importante.Tradurlo.
Ceci est important.Veuillez traduire.
Diese Mitteilung ist wichtig. Bitte übersetzen lassen.
If you have any questions concerning this manual or the operation of your helmet, contact KMDSI [phone] or
by Email at [email protected] or Dive Lab Inc. [phone] or at Div[email protected]
IMPORTANT: A word about this manual. We have tried to make this manual as comprehensive and factual
as possible. We reserve the right, however, to make changes at any time, without notice, in prices, colors, materials,
equipment, specifications, models and availability. Since some information may have been updated since the time
of printing, please contact your local KMDSI dealer if you have any questions. Periodically KMDSI Operations and
Maintenance Manuals are reviewed. Any updates/changes will be posted on the KMDSI website and may be down-
loaded for insertion/correction.
Important Safety Information:
This SuperLite 27 diving helmet is intended for use by trained divers who have successfully completed a recognized
training course in surface supplied diving.
Definition of Signal Words Used in this Manual
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING