Chapter 8 Corrective Maintenance

Chapter 8 Corrective Maintenance 8.1 General This section covers the maintenance and repair of all non-breathing system components of the Kirby Morgan BandMask Models 18 & 28. Correct repairs will result in better communications and improved overall diver comfort and performance in getting the job done. Numbers appearing in parentheses below are location numbers that are used in the blowapart drawing at the rear of this manual. Use only KMDSI original replacement spares when repairing your mask. The use of other manufacturer s parts will interfere with the performance characteristics of your life support equipment and may jeopardize your safety. Additionally, any substitutions will void all warranties offered by KMDSI. All the spare parts in our catalog were specifically manufactured (or inspected and tested) for Kirby Morgan designed helmets and masks. When ordering spares, insist on KMDSI original parts. All parts on Kirby Morgan masks and helmets must be adjusted to their proper torque specifications. See Appendix 1 for a complete listing of torque specifications for each part. Failure to adjust parts to the recommended specifications could lead to mask failure and accidents. This could be fatal. NOTE: For O-ring Removal/Inspection/Cleaning & Installation see Section 6.3.1. For General Cleaning Guidelines, including KMDSI recommended cleaning, sanitizing solutions, and procedures, see Section 6.3. 8.2 Mask Frame Inspection The mask frame of the KMB 18 is constructed using hand laid fiberglass cloth, carbon fiber, mat, and strands, impregnated with polyester resin. It is extremely durable but can be damaged. The KMB 28 is made from injection molded plastic. If the frame is cracked or broken it cannot be repaired but must be replaced. KMB 18 masks that have suffered damage can often be repaired, but repairs to the mask frame must only be accomplished by KMDSI technicians that have been trained and certified in fiberglass repair by KMDSI. Many Kirby Morgan fiberglass helmets and masks still in use today are more than 30 years old. 1) Visually inspect the mask frame exterior for obvious signs of fiberglass damage including cracks, gouges or depressions. NOTE: All gouges and scrapes on the KMB 18 should be covered with tape or paint to reduce absorption of moisture into the fiberglass until repairs can be made. The helmet should not be used if it has any gouges deeper than 1/8 inch. Fiberglass and gel coat repairs should only be completed by a KMDSI trained and certified repair technician that has received certification for helmet shell repairs by KMDSI or Dive Lab Inc. Any signs of cracks or depressions with fractures or other damage should be checked by an authorized KMDSI repair facility or a technician certified in fiberglass repair by KMDSI. Do not attempt to install new thread inserts in the mask frame for the port retainer screws by yourself. If the installation is done improperly, the port retainer can come loose and the mask could flood resulting in drowning. Fiberglass and insert repairs should be only be completed by technicians specifically trained and certified in these procedures. ⅯⅯⅩⅤ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #151015002 111

8.3 Nose Block Assembly 8.3.1 Nose Block Assembly Removal Tools Required: Slip Joint Pliers and a Rag or cloth 7/16 Open-End Wrench 1) Hold the nose block knob with a pair of pliers padded by a cloth, while unscrewing the nose block device with your hand. 2) After the knob is removed, loosen and remove the packing nut. 3) Slip the two o-rings off the end of the shaft of the nose block device and slide the nose block device out through the oral nasal mask. 4) The padded end of the shaft may be bent with pliers to better fit an individual. A larger pad of rubber can also be glued onto this pad. Two o-rings are used to seal the nose block device. Use a protective device or piece of cloth to protect the nose block device knob when you remove it. Removing the nose block device knob. 112 ⅯⅯⅩⅤ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #151015002

8.3.2 Nose Block Device Replacement 1) Prior to reassembly, lubricate the two O-rings. 2) Slide the shaft through oral nasal mask in the mask frame. 3) Place both O-rings on the shaft, followed by the packing nut and the knob. 4) Tighten the packing nut until snug. Do not over tighten, as this will make it difficult to slide the nose block device in and out. 5) Tighten the knob with the pliers, padded by a cloth, while holding the pad end with your hand. 6) You can increase the size of the nose pad by gluing a thicker neoprene pad to the device. Kirby Morgan BandMasks 18 & 28 Do not breathe the fumes from uncured neoprene cement. These fumes are dangerous and can cause unconsciousness. They can also cause long term damage to body tissue. Read and follow all precautions listed on the neoprene cement can. Allow neoprene cement to cure for a minimum of 24 hours before using the mask. Install the nose block device through the interior of the oral nasal mask. Nose block device Viewport (lens) Oral/Nasal Mask Mask frame Blowapart drawing of the nose block device and supporting hardware. O-ring Port Retainer Knob Packing nut ⅯⅯⅩⅤ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #151015002 113

8.4 Face Port 8.4.1 General The face port, or viewing lens, is made of a polycarbonate plastic. Small scratches on the exterior are not important, as they tend to disappear underwater. However, the face port is easily replaced by removing the port retainer and reinstalling a new O-ring and face port. The face port should be replaced anytime cracks are present or anytime nicks and scratches deeper than 1/16 are present or anytime the condition is questionable. Never use aerosolpropelled sprays near the face port of the BandMask. The propellant used in these aerosols can invisibly damage the face port and cause it to shatter upon impact from any strong blow. If the face port fails underwater, the mask will flood and drowning may result. Remove the port retainer screws. 8.4.2 Face Port and Nose Block Device Removal Tools Required: 7/16 Open-end Wrench 1/4 Flat Blade Attachment on Torque Screwdriver Slip Joint Pliers and a Rag or cloth NOTE: Wrap a rag around the nose block knob while removing to prevent chrome damage when turning with pliers. 1) First remove the nose block device knob then the packing nut and slip the O-rings off the nose block shaft. 2) Pull the nose block device out through the interior of the oral/nasal mask. 3) Next, unscrew the remaining twelve port retainer screws. Pull the retainer clear of the mask frame. Take care not to lose the small o-ring on the back of the port retainer. 5) The four whisker spacers must not be misplaced. They will usually be found lodged in the whisker. 6) Remove the old port and sealing O-ring. 4) Be sure not to lose the small O-ring that is located on the back side of the port retainer at the nose block device packing. 114 ⅯⅯⅩⅤ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #151015002

8.4.3 Face Port and Nose Block Replacement Kirby Morgan BandMasks 18 & 28 1) Clean the face port O-ring groove, carefully inspecting it for any damage. The O-ring used with the face port of the Kirby Morgan masks and helmets is made from a special compound and has unique dimensions. It is a softer durometer O-ring than is commonly available. There are no equivalent O-rings manufactured by other vendors. This O-ring must be replaced with a new KMDSI O-ring. Failure to do so could lead to seal failure resulting in leaks or flooding. Lubricate the port O-ring and install in the O-ring groove. 6 o clock position, 9 o clock position, 3 o clock etc.. Repeat this process, one after another, until all screws are evenly torqued to "12" inch pounds and the O-ring has completely sealed the face port. NOTE: Testing of the inserts should be performed once a year or whenever damage is suspected. Part #525-115 Thread Insert Testing Block Kit. Clean the O-ring groove. 2) Lightly lubricate the O-ring with ChristoLube lubricant and replace in the helmet shell. 3) Place the face port into the mask frame making sure the O-ring has been lightly lubricated and is in its groove. 4) Clean and lubricate the small O-ring on the back of the port retainer. 5) Slip the O-ring on the small tube that protrudes from the rear of the port retainer nose block guide. Place the port retainer onto the mask frame, holding it in place against the face port and face port O-ring while the twelve screws, are started but not tightened. When testing the thread inserts, 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 torque of a screw greater than "12" inch pounds can result in serious damage to the surrounding fiberglass in the port area. This can lead to loosening of the port retainer and in extreme instances to flooding of the mask. Always be sure to use a torque screwdriver to check the tension of the port retainer screws. Overtightening can cause damage to the threaded inserts in the fiberglass frame and cause them to loosen. Without the correct tension the port retainer may come loose and the mask could flood. This could lead to drowning. 6) Using a torque screwdriver slightly tighten each opposing screw evenly, i.e. 12 o clock position, ⅯⅯⅩⅤ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #151015002 115

The test procedure, which must be performed by an authorized technician, is designed to identify any inserts that have been damaged, or become loose, requiring replacing. Replacement of inserts should only be completed by an authorized /trained KMDSI technician that has received certification in insert replacement. Minor fiberglass and gel coat repairs must only be completed by technicians that have received fiberglass and gel coat training and certification by KMDSI. 7) Install the nose block device from the interior of the oral/nasal mask and out through the nose block guide on the port retainer. 8) Slide the two lubricated O-rings onto the shaft of the nose block device. 9) The packing nut is threaded into place followed by the nose block device knob. 10) Tighten the packing nut until some resistance is felt when the nose block device knob is pushed in and out. Tighten the nut until it cannot be loosened by hand, then another half turn. If the packing nut is too tight the nose block device cannot slide in and out. 11) The nose block device knob should be tightened to the shaft using a padded pair of pliers, while holding the nose block pad on the inside of the helmet. Don't forget to lubricate the o-rings that seal the nose block device. CORROSIVE The face port is very strong. However, certain chemicals will attack the port and weaken it. Some solvents used for grease removal will also attack the port. Use only mild soap solutions to clean the face port. Improper application of cleaning agents may cause the port to fail without warning. This could lead to drowning. 8.4.4 Special Note Regarding Ports NOTE: There are two different face ports available for KMDSI helmets and masks. One port specifically fits the KMDSI helmets and the KMB 18. One port only fits the KMB 28 BandMask. These two ports are not interchangeable. The face port for the KMDSI helmets and the KMB 18 BandMask is Part #520-004. The face port for the KMB 28 BandMask is Part #520-128. Use only genuine KMDSI face ports. An aftermarket face port s thickness or outer periphery may be incorrect and cause the helmet to flood. It could also be made of inferior materials causing it to fail. This could result in serious injury or death. The face port for KMB 18 and KMB 28 mask are not interchangeable. Do not attempt to use a face port from a KMB 28 in a Kirby Morgan helmet or the KMB 18. Although the port will fit into the helmet shell or KMB 18, it will not seal properly. This could lead to flooding of the mask or helmet, resulting in serious personal injury or death. 116 ⅯⅯⅩⅤ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #151015002

8.5 Hood and Band Keeper Removal and Replacement Tools Needed: - Flat Blade screwdriver - Torque screwdriver w/flat Blade & Phillips Attachments - #2 Phillips screwdriver - Large Phillips screwdriver - RTV Silicone Sealant (Dow Corning #732) 8.5.1 Hood, Bands and Band Keeper Attachment Plates Removal 1. Remove the top and bottom band keeper attachment plates by removing the screws that mount them. 2. Loosen the band adjustment screws and take the hood off of the mask frame. 3. Remove the earphones from the pockets in the hood and remove the hood. 4. Remove the band adjustment screws from the bands and remove the bands from the hood. Kirby Morgan BandMasks 18 & 28 8.5.2 Band Keeper Mount Removal and Replacement 1. To remove the top band keeper mount, remove the three mounting screws. 2. To install the top band keeper mount, screw it onto the front of the port retainer with screws. Use a torque screwdriver and tighten the screws to "12" inch pounds. 3. To remove the bottom band keeper mount, remove the comfort insert (KMB 18 s only) and mounting screws (KMB 18 s only), then remove the screws that hold the mount and carefully pry the mount, that is sealed to the mask frame using silicone sealant, from the mask frame. 4. To install the bottom band keeper mount, clean the old silicone sealant from the bottom band keeper mount and the mask frame. Apply an adequate amount of silicone sealant on the back side of the mount and secure it to the outside of the mask frame using the screws. Wipe off any excess silicone sealant. Comfort Insert (KMB 18 ONLY) Top Band Bottom Band Keeper Mount Top Band Keeper Attachment Plate Spider Hood and Face Seal Bottom Band Bottom Band Keeper Attachment Plate Top Band Keeper Mount Hood, bands, and band keeper arrangement. ⅯⅯⅩⅤ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #151015002 117

8.5.3 Inspect / Replace Inspect the hood, bands, adjustment screws, band keepers and all related parts for damage and/or wear and replace if necessary. 8.5.4 Hood, Bands and Band Keeper Attachment Plates Installation 1. Reinstall the comfort insert (KMB 18 s only). 2. Feed the bands into the hood through one of the large holes on the sides. CAUTION Use good ventilation when using RTV sealant. Fumes from this material may irritate your lungs. Read and follow the directions in the MSDS before using this material. CAUTION Wear hand protection when using RTV sealant. This material may irritate your skin. Read and follow the directions in the MSDS before using this material Feed the bands into the hood. 3. Start the band adjustment screws onto the bands only 2-3 turns. 4. Place the mask frame face down on a work surface and install the earphones into the earphone pockets in the hood. Note that the screws used for the port retainer, band keeper and whisker have a similar appearance, but that all are different lengths. They are not interchangeable. Mount the hood and bands on the mask frame. 118 ⅯⅯⅩⅤ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #151015002

5. Slip the hood and bands onto the mask frame until they are both correctly positioned and centered. Note: On KMB 28 s it may be necessary to place the adjustment block part of the band between the side block and the mask frame first before sliding the other side of the hood onto the mask frame. 6. Using a large Phillips screwdriver lightly snug the band adjustment screws onto the mask frame for the moment. Tighten the band adjustment screws equally on each side checking the position of the hood and bands as you tighten. 7. Place the top band keeper attachment plate over the top, center head harness mount stud on the band and attach it to the mount using the screw. Tighten the screw. Tightening the bottom band keeper. 8. Place the bottom band keeper attachment plate over the lower port side head harness mount stud on the band and attach it to the mount using the screw. Tighten the screw. 9. Using a torque screwdriver, tighten the band adjustment screws to "26" inch pounds. Tightening the top band keeper. ⅯⅯⅩⅤ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #151015002 119

8.6 Replacing the Face Seal Over time, the face seal on the mask may become worn and need to be replaced. It's possible to replace just the seal, but keep your existing hood provided the hood is in good condition. Parts and Materials Needed: 510-505 Face Seal, Wetsuit cement. 8.6.2 Pre-Coat the Material 1. Give the first coat of glue to the edge of the new face seal P/N 510-505. 2. Put the first coat of glue on the hood to the old glue line left behind from the old face seal. Make sure you also pre-coat the ear pocket's and the edge of ear pocket flap. 8.6.1 Removing the Old Face Seal 1) The hood must be completely clean and dry before starting the replacement. It must be rinsed thoroughly in fresh water. 2) Once the hood and old face seal are dry, turn the hood inside out, and using your thumbs roll the face seal down towards the front and remove. 3) Peel off the face seal all the way around the hood. Apply glue to the outer edge of the new face seal. Remove the old face seal from the hood. Remove any excess material left behind, especially the foam on the ear pockets. Apply glue to the inside of the hood. Clean off all remnants of the old face seal. Pre-coat the ear pockets and edge of the ear pocket flap. 120 ⅯⅯⅩⅤ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #151015002

Kirby Morgan BandMasks 18 & 28 3. Allow the glue to dry 20-30 minutes. 4. Give a second coat of glue to the same pieces as in Step 2 (except for the ear pocket flap). 5. Let dry for about 5-10 min. or until the glue is tacky. on the hood material. Make sure the edge of the face seal is attached all the way around the hood. 5. Starting at the chin begin to turn the hood right side out by pulling up on the hood material and making sure the face seal does not crimp up or have any air bubbles. 8.6.3 Installing the Face Seal 1. Find the center of the face seal (eyeball it from top to bottom.) 2. Start by attaching the face seal at the chin, with the foam side down and concentrate on joining the edge of the face seal to the hood first. 3. Align the seal with the hood at the bottom center, work in the face seal from ear pocket to ear pocket by pulling out on the hood material. 4. Next, align top center of the face seal and work down from ear pocket to ear pocket by pulling out Aligning the top center of the face seal. The foam side of the face seal must be oriented correctly in relationship to the hood. The edge of the face seal should be joined all the way around the hood. Start attaching the face seal to the hood at the bottom center of both. Turn the hood right side out. ⅯⅯⅩⅤ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #151015002 121

Kirby Morgan BandMasks 18 & 28 6. Pinch the hood and face seal together all around the front edge of the face seal. 7. Once the face seal is in place with the palm of your hand inside the hood apply pressure to the face seal all around the hood against a hard surface. 8. Pinch all around the inside edge of the face seal. 9. Put a coat of glue to the foam where the ear pocket flap will sit, and a second coat of glue to the ear pocket flap making sure you also glue the edge of the ear pocket. Let it sit for 5-8 min. Wait until it is tacky before you pinch it closed. Again, pinch the edge of the face seal against the hood to make sure they stick together. Pinch the hood and face seal together. Put a coat of glue on the foam where the flap from the ear pocket will connect to the foam. On a firm surface, push the face seal against the hood from the inside. Put a second coat of glue on the ear pocket flap. 122 ⅯⅯⅩⅤ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #151015002

8.7 Communications System 8.7.1 General The communications system in Kirby Morgan helmets and masks requires regular attention and maintenance for proper function. Clear two way speech communications between the diver and the surface crew is one of the most important capabilities of surface supplied diving operations. 8.7.2 Earphone Inspection To inspect the earphones, first carefully remove the earphones from the hood pockets. 1) Remove the (clear) cover first and slide it along the wire to get it out of the way. Remove the earphone protector and then peel back the (black) rear cover. 2) Check the wire connections. They should be solid. 3) Check the mylar diaphragm. If the mylar is torn or loose, replace the entire unit, see "8.7.4 Earphone And Wire Assembly Replacement" on page 125. 4) If the rubber covers are worn or damaged, replace them also. Removing the rubber cover from the earphone. 8.7.3 Microphone Removal and Replacement Tools Required: 1/8 inch flat blade screwdriver 1/4 inch socket on nut driver You will find it much easier to work on the communications system if you remove the hood from the mask. Although this is not essential, the work will generally go more quickly. Earphone Microphone Oral/nasal mask Terminal block Binding post Plug Waterproof Connector Terminal Packing Gland The components of the communications system are shown here in exploded view. 124 ⅯⅯⅩⅤ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #151015002

Inspect the mylar earphone. The microphone is replaced the same as the earphones by removing the wire lugs from the communications posts or terminal block and replacing the entire unit. Location of the communications posts. 1) Remove the nuts and washers from the communications posts. If you are using the optional terminal block this may be where the wires from the earphone and microphone are connected. 2) Lift the terminal lugs off of the communications posts. Note the location of where the terminal wires are connected. 3) Slowly pull the microphone out of the oral nasal mask. The wires that connect it to the communications posts will follow. 4) If you are installing a new microphone or reusing the old one it must be seated in the oral nasal mask. Install the terminal lugs for the new microphone. Note that the wires must go on separate terminals as before. 5) Tighten the nuts carefully, without turning the communications posts. If the posts turn, it means that the seal made by the silicone sealant (RTV) on the mask frame has been broken. If this happens the posts will allow water to leak into the mask. Reinstall the posts per this chapter. 8.7.4 Earphone And Wire Assembly Replacement NOTE: If only the earphone speaker is damaged, it can be replaced by removing the tie-wrap inside of the covers, unscrewing the wire connection and replacing the necessary components. There is no need to completely remove the assembly from the communications module. Install the microphone in the oral nasal mask. Take care not to break the seal made by the silicone sealant where the communications posts penetrate the mask frame. If these posts turn the mask will leak. This could lead to a rapid use of the breathing gas as the diver attempts to keep the mask clear. ⅯⅯⅩⅤ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #151015002 125

Tools Required: 1/8 inch Flat Blade Attachment on Torque Screwdriver 1/4 inch socket on nut driver The earphones may be replaced individually if needed, however, if one is bad, the other earphone will probably need to be replaced soon, too. 1) Remove the nuts and washers from the communications posts. If you are using the optional terminal block this may be where the wires from the earphone and microphone are connected. Take care not to break the seal made by the silicone sealant where the communications posts penetrate the mask frame. If these posts turn the mask will leak. This could lead to a rapid use of the breathing gas as the diver attempts to keep the mask clear. 2) Note the position of the terminal wires. Lift the terminal lugs off of the communications posts. Discard the old earphones. 3) Install the terminals for the new earphones. Note that the wires must go on separate terminals as before. 4) Tighten the nuts carefully, without turning the communications posts. If the posts turn, it means that the seal made by the silicone sealant (RTV) on the mask frame has been broken. If this happens the posts will allow water to leak into the mask. Microphone White Red Earphones LEFT RIGHT Red Black RIGHT LEFT Red Black White Black Red Green Wiring diagram for BandMasks 126 ⅯⅯⅩⅤ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #151015002

8.7.5 Waterproof Connector Kirby Morgan BandMasks are supplied either with a waterproof connector or an optional set of terminal posts. The waterproof connector is subject to failure if the mask receives rough handling. To replace the connector use the following procedure. 8.7.5.1 Waterproof Connector Removal Tools Required: 3/8 inch Open End Wrench 5/8 inch Open End Wrench 11/16 inch Open End Wrench 3/4 inch Open End Wrench 1) On the KMB 18 only, remove the comfort insert. 2) Remove the connector wire lugs from the interior terminal block. 3) Remove the nut from the packing gland on the interior of the mask frame. 4) Separate the connector/packing gland assembly from the mask frame. Kirby Morgan BandMasks 18 & 28 Separate the connector from the mask frame. 5) Place the packing gland in a vice and unscrew the packing nut. 6) Pull the connector through the gland. (Note: It will be much easier to do this if the lugs are cut off the end of the connector first. Save the front and back ferrules and the packing nut. (Note: The entire waterproof connector assembly may also be replaced with Part #505-047 Waterproof Connector Assembly.) Front ferrule Waterproof Connector Back ferrule Terminal O-ring Packing gland Nut Remove the connector wire lugs from the interior terminal block. Components of the waterproof connector. ⅯⅯⅩⅤ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #151015002 127

8.7.5.2 Connector Replacement 1) Lubricate the new connector with silicone grease. 2) Slide the packing nut and ferrules onto the new connector. 3) Feed the connector through the packing gland. If the lugs were removed, solder them onto the connector wires. 4) Check the O-ring on the packing gland. Replace or lubricate as necessary. 5) Install the connector/packing gland assembly in the mask frame. 6) Install and tighten the nut on the packing gland (76) until it is snug. 7) Connect the wire lugs on the connector to the communications posts or terminal block if used. 8.7.6 Communications Posts 8.7.6.1 Communications Post Removal Tools Required; 3/8 inch Open End Wrench 1) Disconnect the communications set as per Section 2) Remove the nut and washer. 3) Pull the communications post away from the mask frame. 8.7.6.2 Communications Post Replacement 1) Clean off all the old RTV silicone sealant from the mask frame and communications post. 2) Apply fresh RTV to the communications post(s). 3) Insert the communications posts into the mask frame. Slides the packing nut and ferrules onto the new connector. Tighten the nut on the packing gland. Apply fresh RTV to communications posts prior to installing. CAUTION Use good ventilation when using RTV sealant. Fumes from this material may irritate your lungs. Read and follow the directions in the MSDS before using this material. 128 ⅯⅯⅩⅤ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #151015002

CAUTION Wear eye protection when using RTV sealant. This material may irritate your eyes. Read and follow the directions in the MSDS before using this material. Kirby Morgan BandMasks 18 & 28 CAUTION Wear hand protection when using RTV sealant. This material may irritate your skin. Read and follow the directions in the MSDS before using this material 4) Install the washer followed by the nuts. Tighten the nuts to "15" pounds of torque. 5) Wipe off all the excess silicone sealant (RTV) from the mask frame. ⅯⅯⅩⅤ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #151015002 129