Kirby MOD-1 User manual

User Guide For
Surface Supplied MOD-1
Document P/N 100-815
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
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.
© MMXXII Kirby Morgan Dive Systems, Inc. All rights reserved. This user guide is made available
for the express use of owner of this Kirby Morgan product. No part of this user guide 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.

2© MMXXII Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 220623001
WARRANTY
USE ONLY KIRBY MORGAN®GENUINE PARTS
Kirby Morgan Dive Systems Inc., (KMDSI) warrants every new helmet, BandMask®, Full Face Mask, SCUBA regula-
tor or air control system (KMACS 5) (each, a Product) to be free from defects in workmanship for a period of three
hundred sixty ve (365) days from the date of purchase from a KMDSI authorized dealer. This warranty covers all
metal, berglass, and plastic parts, but does NOT cover rubber parts, communications components, head cushions,
chin cushions, or foam spacers.
Any defect of the product in workmanship or material covered by this warranty discovered within three hun-
dred sixty ve (365) days from the date of purchase must be promptly communicated in writing to the nearest
authorized KMDSI dealer or (if no such dealer in the buyer’s country) contact KMDSI directly at (805) 928-
7772. No Product returns will be accepted by KMDSI without a returned merchandise authorization (RMA)
number from KMDSI. Upon receipt of the RMA from KMDSI, the buyer should return the defective Product
or part, freight prepaid, to an authorized KMDSI dealer or the KMDSI plant, as directed by the RMA depart-
ment. KMDSI will repair or replace the Product at no charge, within a reasonable time, as it deems necessary.
THIS WARRANTY IS NULL AND VOID IF:
1) The Product is not registered with KMDSI within ten (10) days of purchase, or
2) The Product has not been properly serviced and/or maintained by KMDSI factory trained/approved personnel,
according to factory recommended procedures provided in the manual, along with the KMDSI Appendices Checklists,
and/or Product updates have not been performed as recommended by KMDSI, or
3) Unauthorized attachments or modications have been made to the Product, or
4) The Product has been used for purposes other than those for which it was designed, or otherwise has been abused,
misused, or subjected to unusual conditions, or the Product’s intended service has been exceeded.
EXCEPT AS SPECIFICALLY PROVIDED HEREIN, THERE ARE NO OTHER WARRANTIES, EXPRESS OR
IMPLIED, INCLUDING, BUT NOT LIMITED TO, ANY IMPLIED WARRANTIES FOR MERCHANTABILITY
OR FITNESS FOR A PARTICULAR PURPOSE. THE HELMETS, BANDMASKS AND AIR CONTROL
SYSTEMS COVERED BY THIS WARRANTY ARE MARKETED AND SOLD BY KMDSI SOLELY FOR COM-
MERCIAL OR INDUSTRIAL USE AND ARE NOT A CONSUMER PRODUCT INTENDED FOR PERSONAL,
FAMILY, OR HOUSEHOLD USE.
In purchasing any Product subject to this warranty, the buyer agrees that its sole and exclusive remedy and KMDSI’s
entire obligation in contract, tort, or otherwise under this contract will be repair or replacement at KMDSI’s option of
the Product or any parts which KMDSI determines during the applicable warranty period are defective in workmanship
or material covered by this warranty. All exchanged parts are the property of KMDSI. The buyer’s exclusive remedy
and KMDSI’s entire liability in contract, tort, or otherwise is the payment by KMDSI of the buyer’s actual damages
up to but not to exceed the amount paid by the buyer for the Product.
In no event shall KMDSI be liable to the buyer for indirect, special, incidental or consequential damages (including,
but not limited to, damages for lost prots, lost sales, loss of business opportunity, or for injury to persons or property
arising out of the use of the Products). Any claim or action for breach of warranty must be commenced within one
year following delivery of the Product to the buyer.
Buyer acknowledges that this warranty is the sole and exclusive warranty of the Product and that it supersedes any
and all oral or written representations and undertakings between KMDSI, its dealers, and the buyer relating to the
Products. This warranty allocates the risks of product failure between KMDSI and the buyer, which allocation is
recognized by both parties and is reected in the price of the goods. The buyer acknowledges that they have read
this agreement, understand it, and are bound by its terms.
IMPORTANT: Please register your purchase online at www.kirbymorgan.com/support/product-registration-form. If
you have a problem with the online registration, please contact your Kirby Morgan dealer, or Kirby Morgan directly
by calling [phone], or email [email protected].
Kirby Morgan®thanks you for your purchase.

© MMXXII Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 220623001 3
Table Of Contents
2Warranty
6Definitions of Signal Words and Terms Used in this Guide
7Terms used in this Guide
7Introduction
8Serial Number Location
9Communications
9Hood Assembly
9Regulator
10 Side Block
10 Mask
10 Vent Holes
11 Components of the Surface Supplied Pod
12 CE Marking
13 Notified Body
13 Product Specification
13 Surface Supplied MOD-1 Transport and Storage
14 Minimum Equipment for Surface Supplied Diving
14 Preparing the Surface Supplied Pod for Diving
14 Gas Supply Hoses
15 Main Supply
16 Emergency Gas System (EGS)
16 Installation/Removal of MOD-1 Hood
17 Installation/Removal of Mask Strap
18 Strap Keepers
18 Cleaning the Face Port and Interior Surfaces
18 Communications with the Surface Supplied Pod
18 Communications Check

4© MMXXII Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 220623001
19 Attaching the Umbilical to the Harness
19 One Way Valve Check
20 Oral One Way Valve Check
20 Low Pressure One Way Valve Check
20 Hand Operated Vacuum Pump
21 Communications
22 Removal/Installation of a Microphone
Assembly into the Surface Supplied Pod
22 Removal
23 Installation
25 Microphone Element Removal
25 Removing the Surface Supplied Pod from the Mask
28 Mounting the Surface Supplied Pod to the Mask
32 Pre-Dive
32 Diving Procedures
32 Donning the Mask
35 Equalizing
35 Water Entry
35 Regulator Adjustment Knob
36 Supply Pressure
36 Lens De-Fogging
37 Emergency Procedures
37 Mask Clearing and Dewatering
37 Main Supply Gas Flow Stops
38 Demand Regulator Free Flow
38 Removing the Mask
38 Post Dive Procedures/Checklist
39 Cleaning Procedures
40 Germicidal Solutions Manufacturers
41 Conservation and Storage

© MMXXII Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 220623001 5
41 Scheduled Maintenance
41 Disassembly Guidelines
42 Adjustments and Minor Repairs
42 Supply Pressures
43 Accessories/Spares
43 Prescription Lenses
43 Jumper Hose P/N 855-010
43 One-Way Valve Assembly P/N 505-060
43 Adapter P/N 850-155
43 Over-Pressure Relief Valve P/N 200-017
44 KMDSI Mask Bag P/N 800-905
44 MOD-1 Hood Assembly w/ Bib L/XL, 7 mm P/N 805-125
44 Hood Mount Stud Block P/N 850-095
46 BlowAparts
46 P/N 500-800 Surface Supply Mask BlowApart
47 P/N 805-180 Mask, M-48 MOD-1, w/Vent Passages
48 P/N 805-225 Surface Supply Pod Assembly BlowApart
49 P/N 805-215 Pod Housing Sub-Assembly and
P/N 205-030 Main Tube Assembly BlowApart
50 P/N 805-205 Side Block Sub-Assembly
w/Emergency Valve BlowApart

6© MMXXII Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 220623001
Definitions of Signal Words and
Terms Used in this Guide
The original language of the Kirby Morgan Manuals is English. Translation
into other languages will be provided upon request. KMDSI may charge a
fee for these services.
Throughout this user guide we will use certain words to call your atten-
tion to conditions, practices or techniques that may directly affect your
safety. Pay particular attention to information introduced by the following
signal words:
BDANGER
This word indicates an imminently hazardous situation,
which if not avoided, could result in death or serious injury.
BWARNING
This word indicates a potentially hazardous situation,
which, if not avoided, could result in death or serious
injury.
BCAUTION
This word indicates a potentially hazardous situation,
which if not avoided, may result in minor or moderate in-
jury. It may also be used to alert against unsafe practices.
NOTICE
This word is used to address practices not related to per-
sonal injury.
This user guide contains important safety information and should always be
available to those personnel operating this equipment. Read, understand,
and retain all instructions before operating this equipment to prevent injury
or equipment damage.
If you sell or loan this equipment to another person, be sure that this user
guide accompanies the gear when you transfer possession to them.

© MMXXII Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 220623001 7
Terms used in this Guide
IAW: In Accordance With
EGS: Emergency Gas System
Nose Dam: Located on the inside of the mask, is an extended barrier that
separates the upper (visual) portion of the mask from the lower (oral)
part of the mask.
PPE: Personal Protective Equipment
Introduction
NOTE
Further information pertaining to the Surface Supplied MOD-1
can be found in the Description and Operational Specifications
and General Information KMDSI Products modules, along with
the Kirby Morgan website: www.kirbymorgan.com.
The Surface Supplied Pod is the latest addition to our Modular Full Face
Mask product line.
The new Surface Supplied Pod is constructed of specialty polymers/elasto-
mers and machined components of titanium and high grade stainless steels.
The oral cavity has extremely low volume and greatly reduces residual
levels of CO2. The volume also works well for communications. This Pod is
designed to be operated only in the surface supplied diving configuration.

Serial Number Location
8© MMXXII Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 220623001
Serial Number Location
The M-48 MOD-1 serial number is printed on the left side of the upper
leading edge of the mask frame along with the part number for the mask
and the CE mark on the right hand side.
The serial number is located on the bridge of the Surface Supplied Pod
Assembly.

Communications
© MMXXII Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 220623001 9
Communications
The communications are modu-
lar, with earphone/microphone
elements routed to an externally
mounted communication module
which is easily removed and re-
placed if needed. Current model
has the microphone easily remov-
able as a complete plug-in micro-
phone assembly, or the micro-
phone element can be separated
by itself. Future improvements will
be independent attachments for
the earphone elements as well.
Hood Assembly
Includes earphone pockets. The attached hood is easily removed for re-
placement.
Regulator
The main tube assembly is a slight variation from the main tube assembly
of the balanced SCUBA regulator. All parts are interchangeable except the
balance spacer, P/N 850-170 and adjustable nipple P/N 550-163.
The regulator assembly has been designed and manufactured with pride,
according to Kirby Morgan's world renowned exacting standards for qual-
ity and performance. The Kirby Morgan Balanced SCUBA Regulator is a
high performance regulator which was designed for the professional diver.
The second stage is a modified version of the same regulator used on the
Kirby Morgan 97 helmet and stand alone 455 balanced regulator. Many of
the parts used in this regulator are identical to those used on the KM 97
helmet and 455 balanced regulator. This is helpful to dealers in stocking
parts for service and repair.
Provided it has been purchased new from an Authorized KMDSI Dealer,
your regulator assembly is covered by KMDSI's Limited Warranty. Be sure to
read and fill out the warranty card completely and return the bottom por-
tion within ten (10) days of purchase. Also save your sales receipt. A copy
of your receipt must be presented whenever obtaining warranty service.
Perhaps more than any other piece of diving equipment, your regulator's
function and performance relies greatly on the care and maintenance it will
receive, in addition to regularly scheduled dealer service. Before you dive
with your new Kirby Morgan regulator, it is important to read this guide
in its entirety; to become familiar with its features, as well as the correct
procedures for setup, pre-dive inspection, and post-dive maintenance.

Side Block
10 © MMXXII Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 220623001
Side Block
The linking component to the regulator, from the side block, is made out
of titanium for strength and to eliminate corrosion, and excess weight. The
body and additional metal components are made from 316L stainless steel.
The design of the control valves is extremely simple and easy to maintain.
Mask
All current models of the MOD-1 modular full face masks can be converted
into the Surface Supplied version with the Pod and associated hardware
with a simple modification by an authorized, trained KMDSI dealer.
We do not recommend that this product be operated in contaminated
water. No matter what the Pod configuration used this diving system is
not an acceptable form of protection against biological contaminates.
Vent Holes
The mask skirt has two
vent holes located in each
eye cavity of the mask.
Using the defogger con-
trol knob and inhaling
through the nose, defogs
the lenses with ease.

Mask
© MMXXII Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 220623001 11
Components of the Surface
Supplied Pod
3
8
13
1
2
6
4
11
7
14
9
10
15
5
12
Loc # Description
1 Mask Strap
2 Strap Keeper
3 Hood
4 Ear Pockets
5 Port Weight
6 Regulator
Adjustment Knob
7 Purge Zone
Loc # Description
8 Nose Pocket
9 Oral Cup
10 One way valve
11 EGS valve
12 EGS supply inlet
13 Main gas supply inlet
14 De-Fog Control
15 Guard

Mask
12 © MMXXII Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 220623001
CE Marking
The Surface Supplied MOD-1 has been tested and conforms to the perfor-
mance requirements as set forth in Annex II of Regulation (EU) 2016/425
and, as far as applicable, the EN 15333-1 (Class C). It is fully CE marked
with Surface Supplied POD (P/N 805-225) and the Surface Supplied MOD-1
P/N 500-800.
This mask is intended for diving to maximum depth of 165 fsw/50 msw
and is not intended for the SCUBA diving configuration.
Category of PPE: III
BWARNING
The Surface Supplied MOD-1 has been tested with air
and CE certicated for use with air up to 50 meters. Com-
pressed air must be compliant with the EN 12021. All the
tables reporting the technical data and the pressure of use
are relative to compressed air.
On the underside of Pod Housing Sub assembly the CE mark is printed.
On the Chamber Cover the data reported is the following:
1. The name and address of the manufacturer and year of manufacture
2. CE marking
3. The Model (Surface Supplied Pod)
4. Harmonized reference standard EN15333-1
5. Number of notified body

Notified Body
© MMXXII Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 220623001 13
Notified Body
The Notified Body is:
Eurofins Product Testing Italy
Via Courgnè, 21 – 10156 Torino
ITALY
Identification Number: 0477
Product Specification
805-225 Surface Supplied Pod: 1.95 lbs. (0.88 Kg)
500-800 Surface Supplied MOD-1: 3.8 lbs. (1.71 Kg)
Surface Supplied MOD-1 Transport and Storage
Weight of the package: 6.4 lbs. (2.9 Kg)
Package dimension 12 ×12 × 12 inches

Gas Supply Hoses
14 © MMXXII Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 220623001
Minimum Equipment for
Surface Supplied Diving
The minimum equipment for surface supplied diving with this Pod includes
the following:
• Topside gas supply (either low pressure compressor or high
pressure cylinders)
• Umbilical with breathing gas supply hose, strength member,
communications wire, and pneumo fathometer hose
• One Way Valve (Non-Return)
• Communications box
• Diver worn bail-out bottle with diving harness.
• Bail-out 1st stage regulator with overpressure relief valve and
Submersible pressure gauge.
• If the diver’s main gas supply fails, the diver must have another
source of gas that will enable them to return to the dive station
or to a point where a normal gas supply can be reestablished.
For this reason, an emergency gas supply bailout cylinder must
be used on all dives.
Preparing the Surface
Supplied Pod for Diving
Gas Supply Hoses
Both the main supply (upper) and EGS supply (lower) inlet fittings, found
at the attachment point of the side block, are standard SCUBA threads—⁄
inch-18 male threads. The supply hoses, from the emergency gas system,
should be of sufficient length to allow full movement of the head when
connected to the Pod. ALWAYS connect the main umbilical fitting to the
jumper hose and check valve assembly that was supplied with the mask.
This mask was specifically designed for divers comfort , mobility and safety
by eliminating typical loads that are used with heavier types of diving
equipment supply umbilical attachment.

Main Supply
© MMXXII Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 220623001 15
BWARNING
Never connect the main gas supply hose from the diving
control station to the Emergency Gas valve assembly
(EGS) on the Pod. The EGS tting is the lower tting of
the two that are on the side block. Failure to incorporate a
check valve into the main supply line can result in serious
personal injury or death.
Main Supply
The inlet fitting for the main gas supply is the upper or top inlet fitting on
the side block. A “jumper” SCUBA hose must always be used to connect
the main gas supply through a one way valve and to the side block on
the Pod. A big bore "jumper" hose comes with the pod which includes an
adapter to secure the one way valve directly to the umbilical gas supply
hose. This length is a "suggested" length.
The importance is to NEVER secure the main gas supply, umbilical hose
end, directly to the pod. An additional jumper hose with one way valve
(provided) or manifold block with one way valve must always be used.

Emergency Gas System (EGS)
16 © MMXXII Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 220623001
Emergency Gas System (EGS)
The lower/bottom inlet fitting on the side block is for the EGS gas supply.
It is recommended to use a set of good quality quick disconnecting fittings
with locking sleeves to connect the first stage regulator to a shorter hose
that is secured to the emergency valve inlet located on the side block.
BWARNING
Never connect the main gas supply hose from the diving
control station directly to the side block. If this is done
there is no one way valve protection for the diver in the
event of damage to the umbilical or related equipment. The
diver could be exposed to a serious “squeeze”. This can
result in serious personal injury or death.
If the diver’s main gas supply fails, the diver must have another source of
gas that will enable them to return to the dive station or to a point where
a normal gas supply can be reestablished. For this reason, an emergency
gas supply (bailout) cylinder must be used on all dives. The bailout cylin-
der is worn on the back using a combination backpack and lifting harness.
BWARNING
Do not dive without a diver worn Emergency Gas System.
If the main gas supply is lost, you will have nothing to
breath and may drown.
Installation/Removal of MOD-1 Hood
The hood can be installed with the mask strap on the mask.
1. Bring the hood assembly to
the mask.
NOTE
This usually requires
forming the neoprene
flap at the front of the
hood to the mask face
seal area. This will make
aligning and installing
the retaining screws
easier.

Emergency Gas System (EGS)
© MMXXII Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 220623001 17
2. Align tabs to mask and insert screws.
3. Ensure that, on both sides of the mask, the neoprene material tucks
inside of the leading edge where the lens body and jaw frame meet.
4. Stretch the pull tab away from the mask and over the apex of the lower
jaw frame. Use the nylon pocket to capture the apex of the jaw frame.
Installation/Removal of Mask Strap
The strap keepers MUST be removed to install or remove the mask strap.
We recommend replacing the strap keeper back onto the strap groove
once it has been pulled through the buckle assembly. This will lower the

Strap Keepers
18 © MMXXII Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 220623001
chance of losing the strap keeper and ensure correct orientation into the
strap groove.
The standard mask strap is a five-point semi-stretch head harnesses, P/N
810-007. The mask strap has five straps branching out from a junction at
the bottom OUTER surface of the strap, where “Kirby Morgan” and the
diamond logo can be seen. Each strap leg has many buckle adjustment
“teeth”. Keep in mind that these teeth should be against the divers head
before being threaded into the buckle assembly and the smooth surface
should face outward once it has gone through the buckle assembly.
Strap Keepers
Each of the five straps has a strap keeper. The strap keeper is secured in
a groove found at the end of the strap before the tapered end. The strap
keeper should be installed on the strap, with the small gap in the keeper,
oriented with the smooth side of the strap. The mask strap cannot be
removed from the mask without removing the Strap Keeper. Installing the
strap keeper should be installed after the strap has been threaded through
the buckle assembly.
Cleaning the Face Port
and Interior Surfaces
The mask frame and Pod components are made of high impact plastic. The
flexible face seal and Pod skirts are molded of high-grade injection molded
liquid silicone. The lenses are made of tempered glass. Ensure that the
viewing lenses are clear and clean. Fogging can be eliminated or reduced
by thoroughly cleaning the interior of the lens and applying a good qual-
ity anti-fog solution. Follow the manufacturer’s recommendations for use.
Communications with the
Surface Supplied Pod
The microphone is connected to the module through a connector body and
uses a wire jumper assembly which allows rapid removal and replacement
without having to remove the communications assembly from the Pod. The
microphone element is captured by a shroud that is designed to refine the
diver’s voice transmission. It is easily removable, but not necessary when
completing a post dive sanitization and inspection.
Communications Check
Check the communications system for proper operation. Put the mask on
without tightening the mask straps and talk normally into the mask. A slow

Strap Keepers
© MMXXII Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 220623001 19
count up to five and back to one from the diver to the topside operator
and topside operator to diver should be the bare minimum test performed
to ensure microphone and speaker levels are at a good starting point.
Attaching the Umbilical to the Harness
Most commercial divers wear a harness (separate from the weight belt)
that is used for several purposes. The harness is fitted with large metal
rings (usually brass or stainless steel). The umbilical is hooked into one of
these rings to keep any strain off the mask. In addition, the rings on the
harness are used to hang tools and other equipment. Usually, the harness is
also designed to provide a means of lifting an unconscious diver from the
water. A harness is the best method of securing the emergency breathing
gas to the diver.
BWARNING
Never dive without attaching the umbilical to a proper har-
ness assembly that meets industry standards and can be
used to safely lift an unconscious diver out of the water.
The lift point must be done in a way so there is no pull on
the diver’s mask. Never allow the umbilical to pull on the
mask directly or the diver could suffer a neck injury.
One Way Valve Check
The one way valve must be tested daily, prior to commencement of diving
operations.
1. There are three methods for testing the one way valve.
2. Orally
3. Using regulated low pressure.
4. Using a hand operated Vacuum Pump
BWARNING
The one way valve must be tested daily, prior to com-
mencement of diving operations. Failure of the one way
valve could cause serious injury or death.
The free flow valve (de-fog control) must be open when performing the test.

Oral One Way Valve Check
20 © MMXXII Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 220623001
Oral One Way Valve Check
1. Test the one way valve for proper operation by blowing and sucking
(cycling) on the main gas supply inlet. No gas should be drawn through
the one way valve. If you are able to suck any air through the one way
valve, it is not working properly and should not be used.
Low Pressure One Way Valve Check
1. Close the emergency and defogger control knobs and screw in the
adjustment knob on the regulator all the way.
2. Attach a regulated gas supply (normally using the EGS system), ad-
justed to between 135–150 psig (9.3–10.3 bar), to the emergency valve.
3. Open the emergency supply valve all the way and then slowly open
the gas supply.
4. Check for gas exiting from the one way valve. There should be no gas
exiting the umbilical adaptor. If any gas exits through the one way
valve it is not working properly and should not be used.
Hand Operated Vacuum Pump
1. Open Free Flow valve.
2. Connect hand vacuum pump and vacuum with gauge to one way valve.
3. Pump hand vacuum pump until gauge reads 20 inches of vacuum.
4. Observe gauge, if needle moves out of the prescribed range the one
way valve is not working properly and should not be used.