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Kirby Morgan 37 & 57

Chapter 7.0

Breathing System Maintenance and Repairs

7.1 Introduction

This chapter covers the maintenance and repair of all

components of the breathing system. The breathing

system includes the one way valve, the emergency

valve, the side block, the bent tube assembly, the

demand regulator, and the oral/nasal mask.

The breathing systems on all Kirby Morgan helmets

and masks are simple and highly reliable. The fact that

they can continue to operate when the components are

not in a well-maintained condition can cause divers

to become complacent about maintenance.

Your life depends on the correct function of this

equipment!

While Kirby Morgan helmets and masks are simple

to maintain, like any type of life support equipment,

they do require regular periodic maintenance to func-

tion properly.

All parts disassembled should be thoroughly cleaned

using the methods described in the Appendix in the

rear of this manual. Components that require the use

of lubricants, sealing and thread locking compounds

should also be maintained.

Most fasteners have a torque value, it is imperative that

all fasteners which have a torque value be tightened

to the torque speciﬁcations as outlined by the proce-

dure, or as listed in appendix 1. If in doubt as to the

proper torque setting, contact your local authorized

repair facility or KMDSI.

7.2 One Way Valve

NOTE: The one-way valve assembly should be disas-

sembled, cleaned and the three O-rings should be

replaced at least annually. Damaged and/or corroded

parts should be replaced. A repair kit is available for

replacement parts (525-330).

7.2.1 Disassembly Of The One Way Valve

Tools Required:

Soft Jaw Vice

1 inch Open End Wrench Attachment on Torque

Wrench

(If no vise is available use a backup 1 inch open end

wrench)

To disassemble and inspect the one way valve as-

sembly:

1) The one way valve assembly must be removed

from the side block. Use the open end wrench to

remove it.

2) After the one way valve has been removed, use two

wrenches or hold the hex part of the body in a soft jaw

vise while removing the seat with a wrench.

As the seat is removed, the wiper and the O-ring

will slide out in place in a groove on the seat. The

Use two wrenches or hold the hex part

of the body in a vise while removing or

turning the seat with a wrench. Do not

use pliers on the main body of the one-

way valve. You may damage the valve if

pliers are used.

CAUTION

Summary of content (50 pages)

PAGE 1
Kirby Morgan 37 & 57 Chapter 7.0 Breathing System Maintenance and Repairs 7.1 Introduction This chapter covers the maintenance and repair of all components of the breathing system. The breathing system includes the one way valve, the emergency valve, the side block, the bent tube assembly, the demand regulator, and the oral/nasal mask. 7.2 One Way Valve NOTE: The one-way valve assembly should be disassembled, cleaned and the three O-rings should be replaced at least annually.
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Kirby Morgan 37 & 57 Adapter Wiper Spring O-ring Seat O-ring O-ring Poppet Body Correct assembly order of the one way valve. poppet and the poppet O-ring usually come out in the seat being followed by the spring. The only functional part remaining in the valve body is a non-moving, pressed-in cage. The function of the cage is to prevent the poppet O-ring from blowing out of place during high flows. Do not remove the pressed in cage. This can only be done at the factory.
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Kirby Morgan 37 & 57 7.3 Side Block Assembly 7.3.1 General The side block should be overhauled at least annually, or whenever components show signs of wear, damage or do not function smoothly or properly. Minimum replacement components during overhaul includes all O-rings. A repair kit is available for replacement parts (Part #525-311).
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Kirby Morgan 37 & 57 flat black finish inside the helmet. 6) If you plan to rebuild the side block assembly, it should be done at this time, while the side block is off the helmet. Overhaul the defogger valve and emergency valve in accordance with this chapter. Overhaul the one-way valve in accordance with this chapter. 7.3.4 Side Block Assembly Replacement If a new side block is being installed, make sure it aligns correctly in the holes of the helmet shell before applying RTV silicone sealant.
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Kirby Morgan 37 & 57 WARNING If it is, it must be cleaned out prior to diving. Use silicone sealant in a well ventilated area. Do not breathe the fumes from uncured silicone sealant. 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 silicone sealant tube and Material Safety Data Sheet. WARNING Do not dive the helmet until the sealant has had time to cure.
PAGE 6
Kirby Morgan 37 & 57 7.4 Defogger Valve 7.4.1 Disassembly of the Defogger Valve Tools Required: 3/8 inch Slotted Flat Blade Screwdriver 13/16 inch Open End Attachment on Torque Wrench 2) Next, unscrew the bonnet. Its o-ring will come off with it. The valve stem, o-ring, and washer usually come out with the bonnet and can be pushed out of the bonnet once removed from the side block. 3) If the stem remains in the side block body it can be lifted out after the bonnet is removed.
PAGE 7
Kirby Morgan 37 & 57 Air Train The Side Block assembly and it’s associated parts. Air Train Gasket Helmet shell Side Block Bolt Stud Seat Valve Stem LP Plug Teflon washer Bonnet Washer Knob Nut Bent Tube O-ring Spring 7.4.
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Kirby Morgan 37 & 57 7.5 Emergency Valve Assembly The Emergency valve control knob is not interchangeable with the defogger valve control knob. WARNING The control knob for the emergency valve and the defogger knob are not interchangeable. Use only the correct knob for the appropriate valve. 7.5.
PAGE 9
Kirby Morgan 37 & 57 5) To remove the emergency valve body from the side block the one way valve assembly must first be removed. 6) If the emergency valve body was removed, clean and inspect the pipe thread and inspect for damaged threads, cracking or distortion. Replace the emergency valve if any damage is present. Re-tape threads with Teflon tape, 11/2 wraps starting two threads back, tighten using good engineering practice.
PAGE 10
Kirby Morgan 37 & 57 WARNING The control knob for the emergency valve and the defogger knob are not interchangeable. Use only the correct knob for the appropriate valve. and rotate the stem all the way out, then back again. The rotation must be smooth. If “hard spots” or unevenness are felt during the rotation, the stem may be bent and could need replacement. 8) Tighten the packing nut with a torque wrench until moderate resistance is felt when turning the knob. Torque to 50 inch pounds after seating.
PAGE 11
Kirby Morgan 37 & 57 7.6 Bent Tube Assembly 7.6.1 General The bent tube assembly provides breathing gas flow from the side block assembly to the regulator assembly on the Kirby Morgan 37. Both ends of the bent tube assembly disconnect for complete removal. The Oring and the Teflon O-ring should be replaced during normal overhauls or any time these components are deemed unserviceable.
PAGE 12
Kirby Morgan 37 & 57 7.6.4 Installation of the Bent Tube Assembly Tools Required: 11/16 inch Open-end Torque Wrench Attachment 7/8 inch Open-end Torque Wrench Attachment 7/8 inch Open-end Wrench Normal minimum replacement parts during overhaul: O-ring, Teflon® ring 1) Lightly lubricate the bent tube O-ring and install in the O-ring groove at the regulator end of the bent tube, then install new Teflon® O-ring at the side block end. 2) Push the regulator end of the bent tube assembly into the inlet nipple.
PAGE 13
Kirby Morgan 37 & 57 7.7 SuperFlow 350 Demand Regulator 7.7.1 General Regulator Information While the regulator systems on all Kirby Morgan helmets are simple and highly reliable, the breathing resistance will increase if the demand regulator on your helmet is not maintained or adjusted properly. The demand regulator must receive regular maintenance to assure the best performance possible.
PAGE 14
7.7.3 Inspection of SuperFlow 350 Regulator Body Interior Tools Required: 1/4 inch Flat Blade Attachment on Torque Screwdriver Kirby Morgan 37 & 57 NOTE: Older regulator clamps, when properly torqued, had a gap of approximately 1/32” to 1/16” between the retaining clamp surfaces when fully tightened. All new clamps when properly torqued, have little or no gap between the retaining clamp surfaces. 7.7.
PAGE 15
Kirby Morgan 37 & 57 Inspect the washer and o-ring. 9) Inspect the inside of the adjustment tube on the regulator body to be sure there is no corrosion and the adjustment assembly can travel freely. Ensure the alignment tube is not bent or misaligned from impact, and that the threads are clean. Shake out the spacer, spring set, and piston. is over the hole. The adjustment knob can be held against the wood block allowing the roll pin to be driven into the 1/4” hole.
PAGE 16
Kirby Morgan 37 & 57 NOTE: Ensure the adjustment shaft (85) rotates smoothly. 6) Thread the packing nut onto the regulator body (81) and tighten with the 3/4” torque wrench to 40 inch pounds after seating, turn the knob all the way in and all the way out making sure there is no interference. 7.7.
PAGE 17
Kirby Morgan 37 & 57 7.7.
PAGE 18
Kirby Morgan 37 & 57 drilled through it to support the knob. Position the knob so the roll pin is over the hole. The adjustment knob can be held against the wood block allowing the roll pin to be driven into the 1/4 ” hole. 8) Remove the inlet nipple from the regulator body. The O-ring should be replaced if a scheduled overhaul is being performed. 9) Place the castle wrench in the inlet nipple side of the demand regulator over the soft seat of the inlet valve to prevent the inlet valve from rotating.
PAGE 19
Kirby Morgan 37 & 57 7.7.8 Inspection of SuperFlow 350 Demand Regulator Parts After the regulator has been disassembled, clean and inspect all parts. Any parts showing signs of wear, damage or deterioration should be replaced. If this is an annual overhaul KMDSI recommends replacement of the inlet valve seat, adjustment nut, O-ring on inlet valve, O-ring on adjustment shaft, washer on the adjustment shaft. A rebuild kit is available for replacement parts (Part #525-309).
PAGE 20
Kirby Morgan 37 & 57 7.7.9 Reassembly of the SuperFlow 350 Demand Regulator NOTE: Use the blow-apart in the back of the manual to help ensure correct assembly. 1) Install the exhaust flange, gasket, and screws onto the regulator body. Use Loctite 222 to secure the screws. Tighten the screws to 6 inch pounds. 2) Trim off any excess material from the gasket that might interfere with the operation of the exhaust valve.
PAGE 21
Kirby Morgan 37 & 57 5) Using the nut driver from the tool kit, run the nut onto the inlet valve stem approximately 1 1/2 to 2 turns, leaving enough slack to allow installation of the lever. With the inlet valve pressed in, the washer and spacer must be loose on the inlet valve stem so the lever can be installed. 6) Check the roller lever. The lever legs MUST be parallel to each other and free of any nicks or burrs.
PAGE 22
Kirby Morgan 37 & 57 8) While holding the lever down, install the inlet nipple with its O-ring into the regulator body. Using the torque wrench, tighten the inlet nipple to 40 inch pounds. 9) Lightly lubricate the piston and spacer. Install the piston, spring set and spacer into the adjustment tube of the regulator body, as shown in the blow-apart drawing. 10) Lightly lubricate the new O-ring then install the new washer and O-ring on the adjustment shaft.
PAGE 23
Kirby Morgan 37 & 57 14) Rotate the adjustment knob in i.e., clockwise, several turns, then recheck the torque one more time. Ensure the adjustment shaft rotates smoothly and there is no binding. 15) Stretch the Quad-Valve main exhaust body onto the exhaust flange of the regulator. Rotate as needed so the port and starboard whiskers can be installed. 16) For the old double exhaust or single exhaust, stretch the exhaust whisker onto the exhaust flange of the regulator.
PAGE 24
Kirby Morgan 37 & 57 7.7.10 Tuning the SuperFlow 350 Regulator 1) Remove the clamp, cover and diaphragm. 2) Screw the adjustment knob (clockwise) all the way in, towards the regulator body. 3) Pressurize the regulator to between 120-150 p.s.i.g. of supply pressure. 4) Screw the adjustment knob out (counterclockwise) until the regulator starts to free flow, then screw the adjustment knob in (clockwise) until the free-flow just stops. Depress the lever several times to ensure the free-flow has stopped.
PAGE 25
Kirby Morgan 37 & 57 Use the disk end of the KMDSI wrench to bend the lever down. CAUTION The legs of the lever must be properly aligned in the same plane. If one leg is up and the other is down, the regulator will not perform properly. 12) Replace the diaphragm and the cover. Test the purge button. Continue until proper tolerances are reached. 92 © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved.
PAGE 26
7.7.11 SuperFlow 350 Regulator Steady Flows When Pressured Up: Special Tools Used Tools Required: Small flat blade screw driver. Small jewelers screw driver or metal scribe. Needle nose pliers. KMDSI regulator tool kit if available. A few words about the demand regulator: The demand regulator is rugged and reliable. However, to maintain optimum performance it should be checked prior to each diving day in accordance with the brief procedure Demand Regulator Test for Correct Adjustment, Fully Assembled.
PAGE 27
Kirby Morgan 37 & 57 a regulator that has been in service. Usually levers only require bending in new installations or because of damage during disassembly. 10) Install the clamp and clamp screw. Tighten the screw to the correct torque (see appendix for torque specifications). 11) Again, press on the purge button in the cover. It must have 1/16 inch (1.5 mm) minimum and 1/8 inch (3.0 mm) maximum free travel before it contacts the diaphragm. If there is more than 1/8 inch (3.
PAGE 28
Kirby Morgan 37 & 57 7.8 Oral/Nasal 7.8.1 Oral Nasal General Information The oral/nasal mask is used to control and maintain low carbon dioxide (CO2) levels in the helmet and to isolate the microphone for more intelligible speech. WARNING Never dive with a Kirby Morgan helmet without a properly functioning oral/nasal mask. Without an oral/nasal, dangerous levels of carbon dioxide may accumulate in the helmet. This can lead to unconsciousness and death. Equalizing Device Oral/Nasal Mask 7.8.
PAGE 29
Kirby Morgan 37 & 57 7.8.3 Oral/Nasal Replacement 1) Snap the oral/nasal over the regulator mount nut (45). 2) Reinstall the microphone. 3) Reinstall the nose block device. 4) Ensure that the oral/nasal valve has been installed correctly. Correct installation of the oral/nasal valve is extremely important to your safety. WARNING The oral/nasal valve must be replaced correctly to provide gas flow in the proper direction.
PAGE 30
Kirby Morgan 37 & 57 7.9 Quad-Valve™ Exhaust Assembly The Quad-Valve™ exhaust became standard on the Kirby Morgan 37 helmet as of March 2005. This is a superior exhaust system that ties together the regulator exhaust and the helmet exhaust into one unit with exceptionally low exhalation resistance. 1) Removal of the Quad-Valve™ Assembly is started by cutting the tie wrap that holds the assembly to the regulator.
PAGE 31
Kirby Morgan 37 & 57 NOTE: The exhaust valve and whisker exhaust valve inserts must be placed into the Quad-Valve exhaust main body correctly to provide gas flow in the proper direction. The flow must be from the inside of the Quad-Valve exhaust main body out to starboard whisker and port whisker. 7.9.2 Quad-Valve™ Exhaust Valves NOTE: It is necessary to first remove the regulator and exhaust assembly from the helmet to replace the exhaust valves. 7.9.2.
PAGE 32
WARNING The exhaust valves must be correctly installed in the exhaust valve inserts or they will not seal correctly. This could lead to a backflow of water into the helmet, which could expose the diver to any contaminants that are in the surrounding water. Depending on the contaminants, this could lead to serious personal injury or death.
PAGE 33
Kirby Morgan 37 & 57 7.10 Water Dump Exhaust Body The water dump exhaust assembly is mounted onto the bottom of the helmet by three screws that are installed on the inside of the helmet shell. RTV silicone sealant is used to seal the water dump body to the helmet shell. 7.10.1 Water Dump Valve Removal Tools Required: Flat Blade Screwdriver 1) The Quad Valve cover can be removed by unscrewing the two screws.
PAGE 34
Kirby Morgan 37 & 57 7.11 Reinstalling the Quad-Valve™ Exhaust Assembly Once the Quad-Valve™ exhaust has been reassembled, it may be mounted back on the helmet. 1) Begin to re-install the demand regulator into the mounting hole in the helmet shell, but insert it only about halfway in. This will allow the stainless steel adapter cover to align easier with the main exhaust body. WARNING Use only KMDSI original replacement spares when repairing your helmet.
PAGE 35
Kirby Morgan 37 & 57 7.12 SuperFlow 450 Stainless Balanced Regulator 7.12.1 General The SuperFlow 450 is another high performance regulator from Kirby Morgan. This is an exceptionally compact, but high performance regulator. 3) Turn on the gas supply. 4) Rotate the Flex Knob out counterclockwise slowly, three full turns. 5) Lightly depress the purge button several times and ensure the gas flow is stable. 6) Push in gently on the cover of the regulator.
PAGE 36
7.12.2 Adjusting the SuperFlow 450 Tools required: Flat blade screwdriver 11/16 inch Open-end Attachment on Torque Wrench 7/8 inch Open-end Attachment on Torque Wrench 7/8 inch Open-end Wrench 1 inch Open End Wrench 1/4” to 5/16” Dowel Rod sharpened by pencil sharpener Kirby Morgan 37 & 57 4) If the regulator did not free flow when the regulator cover was pushed in, turn the adjustment nipple OUT 1/16 of a turn. Only small adjustments are needed to tune the regulator.
PAGE 37
Kirby Morgan 37 & 57 7.12.3 SuperFlow 450 Demand Regulator Bias Adjustment Field Service with Demand Regulator on Helmet It is not necessary to remove the regulator from the helmet to perform field maintenance. Tools Required: 1/4 inch Flat Blade Screwdriver on Torque Wrench 1” Open End Attachment on Torque Wrench 1/4” to 5/16” dowel rod sharpened by pencil sharpener. Remove the diaphragm and inspect it carefully. If it is torn or punctured it must be replaced.
PAGE 38
Kirby Morgan 37 & 57 5) Using the 1” open end wrench, loosen the packing nut about 1 turn. While depressing the lever arm, grasp the flex knob and pull it straight away from the regulator body. This will remove all of the main components of the regulator valve mechanism as a single, easy to handle unit. 6) Using a 7/8” wrench, remove the bent tube adapter and o-ring. 7) Unscrew the flex knob assembly from the main tube. 8) Remove the o-ring from the flex knob assembly packing nut.
PAGE 39
Kirby Morgan 37 & 57 Remove the balance spacer, spring, inlet valve and seat from the main tube. When you pull the flex knob assembly out, the main tube and related parts will follow. 11) Slide the balance spacer, spring, inlet valve assembly out from the main tube. 12) Unscrew the adjustment nipple (turn it “out”) from the main tube. This may require lightly tapping on the tube to dislodge the parts. 13) Inspect all parts for signs of wear or damage and replace if necessary.
PAGE 40
Kirby Morgan 37 & 57 tube. The square opening on the main tube must be exposed. 19) Spread the arms of the lever just enough to install it on the main tube. Insert the balance spacer and spring in the main tube. When it is properly installed the spacer will engage the inlet valve. Close-up detail of the inlet valve. Thread the adjustment knob onto the main tube. Inserting the inlet valve into the main tube. 20) Study the features of the inlet valve assembly.
PAGE 41
Kirby Morgan 37 & 57 26) Inert the adjustment nipple into the main tube on the end opposite end from the adjustment knob. Using a flat blade screwdriver, thread the nipple into the tube slowly. As soon as you see any movement of the lever stop screwing the nipple in. Turn in on the flex knob until an audible click is heard. 27) It is recommended that the regulator sit for 24 hours before any further assembly is completed. This will allow the seat to conform itself correctly to the inlet nipple.
PAGE 42
Kirby Morgan 37 & 57 7.12.4 SuperFlow 450 Regulator Removal Required Tools: 11/16 inch Open-end Attachment on Torque Wrench 7/8 inch Open-end Wrench, Torque Wrench and 1 3/8 inch Socket 1 /4 inch Flat Blade Attachment on Torque Screwdriver 1) Remove the bent tube assembly, per this chapter. 2) Remove the screws, kidney plates and whisker spacers from the whiskers. Remove the regulator from the helmet. Be sure to remove and set aside the whisker spacers. 3) Remove the nose block device per chapter 8.
PAGE 43
Kirby Morgan 37 & 57 7.12.5 SuperFlow 450 Disassembly Required Tools: 1” Open end attachment on torque wrench 1/4 inch Flat Blade Attachment on Torque Screwdriver 3/8” Dowel Rod 1) Remove the screws and washers on either side of the regulator cover. 2) Unscrew the cover retaining ring. 3) Remove the cover and diaphragm. Inspect the diaphragm for holes or tears. If it torn or punctured it must be replaced. Inspect the interior of the regulator for foreign matter and remove if necessary.
PAGE 44
Kirby Morgan 37 & 57 o-ring Balance spacer Inlet valve Spring Main tube Seat Bearing clip Lever o-ring o-ring Details of the SuperFlow 450 main tube and associated parts. Adjustment nipple 8) Remove the adjustment shaft from the flex knob. With the shaft out, grab the packing nut with one hand and the flex knob with the other and bend. There is a boss on the knob that will pop loose from the packing nut. 9) Remove the o-rings from the adjustment shaft and packing nut.
PAGE 45
Kirby Morgan 37 & 57 7.12.6 Assembly of the SuperFlow 450 Regulator Required Tools: 11/16 inch Open-end Attachment on Torque Wrench 7/8 inch Open-end Wrench, Torque Wrench and 1 3/8 inch Socket 1 /4 inch Flat Blade Attachment on Torque Screwdriver 1) Inspect the interior of the regulator body and make sure that it is clean and there is no foreign matter. 2) Install the o-ring into the regulator body. 3) Place the exhaust valve insert in the regulator body.
PAGE 46
Kirby Morgan 37 & 57 Install the o-ring on the main tube. Install the lever on the main tube. Note the bearing clip fastens on the opposite side of the tube. 12) Using a clean wooden dowel rod, that has been sharpened in a pencil sharpener and inserted in the open end of the inlet valve, properly align and insert the inlet valve into the main tube. If this is done properly, the lever should lift up. If it does not, the valve has not been inserted correctly. Install the o-ring on the inlet nipple.
PAGE 47
Kirby Morgan 37 & 57 16) Install the o-ring in the packing nut. 17) Fit the flattened end of the adjustment shaft into the flex knob. 18) Screw the adjustment shaft into the packing nut until it clicks. 19) Screw the packing nut and the entire flex knob assembly onto the main tube until it is hand tight. Slide the main tube and associated parts into the regulator body. Screw the flex knob assembly onto the main tube.
PAGE 48
Kirby Morgan 37 & 57 28) Retighten the packing nut to 30 inch pounds. 29) Insert the lock clip into the groove on the packing nut inside the regulator body. Push down on the clip with a screwdriver until it is fully installed on the packing nut. 30) Turn the flex knob in towards the regulator body until you hear a click. This indicates the maximum distance the adjustment shaft will travel. Next, back the knob out completely until it stops. Thread the bent tube adapter onto the main tube.
PAGE 49
Kirby Morgan 37 & 57 7.12.7 SuperFlow 450 Regulator Installation Required Tools: 11/16 inch Open-end Attachment on Torque Wrench 7/8 inch Open-end Wrench, Torque Wrench and 1 3/8 inch Socket 1 /4 inch Flat Blade Attachment on Torque Screwdriver 1) Install the tie wrap on the center section of the exhaust whisker, named the exhaust main body and tighten. 2) Install the spacer on the regulator tube and install the regulator assembly and spacer on the helmet.
PAGE 50
Kirby Morgan 37 & 57 3) Install the sealing o-ring and regulator mount nut. Do not tighten the nut at this time. 4) Tighten the screws that connect the exhaust main body to the quad exhaust cover. 5) Install the oral nasal mask per this chapter. 6) Install the nose block device per chapter 8. 7) Install the bent tube assembly, per this chapter. 8) Tighten the regulator mount nut to 75 inch pounds. 9) Install the screws, kidney plates and whisker spacers from the whiskers.