Professional Documents
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DIVING HELMET
OPERATIONS AND MAINTENANCE
MANUAL
SuperLite-17, SuperLite-27, SuperLite-17C, Band Mask, Kirby Morgan, DCS-2A, DCS-3, and
KMB are all registered trade marks of Diving Systems International.
© 2001 Diving Systems International. All rights reserved. No portion of this manual may be repro-
duced in any form without the express written permission of Diving Systems International.
Docu# 010502002
BLANK
RECORD OF CHANGES
It is the responsibility of the owner of this product to register their ownership with Diving
Systems International with the warranty card provided. The purpose of this card is to establish a
means of communication that allows DSI to contact the user regarding this product. The user must
notify DSI of any change of address by the user or sale of this product.
All changes/revisions to this manual must be recorded in this document to ensure this
manual is kept up-to-date.
MAINTENANCE LOG
SUPERLITE-17
Helmet Serial Number:
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.
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.
If you have any questions regarding the information in this manual, or the
operation of your mask, call Diving Systems International at (805) 965-8538.
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 DSI dealer if you have any questions.
WARNING: Follow all the instructions in this manual carefully and heed all safety
precautions. Improper use of this diving helmet could result in serious injury or death.
DANGER: Diving Systems International (DSI) warns all divers who use the
SuperLite 17 diving helmetto be sure to use only DSI original spare parts from a DSI
authorized dealer. Although other parts, O-rings and fittings may appear to fit on the
SuperLite 17 diving helmet, they may not be manufactured to the same standards
maintained by DSI. The use of any spares other than DSI original parts may lead to
equipment failure and accidents.
Read this manual before using or maintaining the helmet, even if you have experience with other
diving helmets. If you have purchased the helmet new from a dealer, be sure to send in the warranty
registration card so we may keep you informed regarding any safety notices that affect this product.
If you resell or loan this helmet to another diver, be sure this manual accompanies the helmet and
that the person reads and understands the manual.
WARNING: This helmet was completely checked and should be ready to dive as
it was shipped from the factory. However, it is always the diver's responsibility to check
all the components of the mask prior to diving.
WARNING: Any and all fiberglass repairs done to this helmet MUST be done by
a factory trained repair facility. NEVER paint or re-gelcoat your shell as this can hide
dangerous damage to your shell.
This manual is supplied to the original purchaser of this helmet. If you have any questions about the
use of the helmet or you need another copy of this manual, Part Number 100-002, contact Diving
Systems International. If you have any questions regarding the use, maintenance, or operation of
this helmet, contact Diving Systems International at (805) 965-8538.
Diving Systems International regards the use of any breathing gas mixture greater than 23.5%
oxygen to be treated as oxygen. This belief is in keeping with the recommendations set forth
by the National Fire protection Association (NFPA), Compressed gas Association (CGA), and
the American Society for Testing and Materials (ASTM).
Any diving helmet, full face mask, regulator, control console or breathing life support item
manufactured or sold by Diving systems International must not be used with breathing gas
mixtures in excess of 23.5% oxygen without first ensuring that all gas transporting components
have been cleaned for oxygen service, have oxygen compatible soft goods lubricated with an
approved oxygen compatible lubricant such as Krytox or Christo Lube grease.
WARRANTY INFORMATION
Diving Systems International warrants every new mask, helmet, or DCS (Dive
Control System) to be free from defects in workmanship for a period of ninety (90)
days from date of purchase. This warranty covers all metal, fiberglass, and plastic
parts. This warranty does NOT cover rubber parts, communications components, or
headliners. In addition, due to the electrolytic nature of underwater cutting and weld-
ing, chrome plating cannot be warranted when the diver engages in these activities.
Should any part become defective, contact your nearest authorized DSI dealer. If
there is no dealer in your area, contact DSI directly at (805) 965-8538. You must have
a return authorization from DSI prior to the return of any item, Upon approval from
DSI, return the defective part, freight prepaid, to the DSI plant. The part will be re-
paired or replaced at no charge as deemed necessary by DSI.
1) The product is not registered with DSI within ten (10) days of purchase.
2) The product has not been properly serviced and/or maintained according to
the appropriate DSI manual. In addition, the user is responsible to ensure that
all product updates as recommended by DSI have been performed.
4) The product has been abused or subjected to conditions which are unusual
or exceed the product’s intended service.
Be sure to complete the enclosed warranty card and return it to DSI immediately.
No warranty claims will be honored without a satisfactorily completed warranty card
on file at DSI.
Emergency valve
Non-return valve
Regulator
Neck dam
Neck clamp
Waterproof connector
This manual will refer to location numbers in specific drawings, or in the exploded view
which is in the back of this manual. These numbers are called “location” numbers. They
are used to find the referred to parts in the drawings in this manual only. They are NOT
the part number. Next to the exploded drawing is a list of the “location” numbers that
match the Kirby Morgan part numbers along with what the part is called.
Always check the part number when ordering to make sure it is correct. When ordering,
always specify the helmet model number and serial number as well.
SECTION 1.0
GENERAL INFORMATION
1.1 INTRODUCTION
Diving Systems International, Inc. (DSI) is
the same corporation (with only a name
change) that started as the Kirby Morgan
Corporation in 1965. Kirby Morgan is a
registered trademark for our products.
Diving Systems International has a worldwide dealer network that makes it possible to get parts for
your Kirby Morgan diving helmet almost anywhere in the world.
1) The neck dam/yoke (31) design helps to maintain a low volume in this helmet.
2) The head cushion (1) attaches just inside the bottom of the helmet, keeping it in place when the
diver dons the hat.
3) The helmet is available in two configurations. The SuperLite-17A accepts the umbilical up the front
of the diver’s chest. The SuperLite-17B accepts the umbilical over the diver’s shoulder.
4) The helmet incorporates a new, heavy duty pull pin latch catch assembly (22) that helps ensure the
neck clamp does not open accidentally.
6) The neck clamp (7) on this helmet will mechanically “break” any underpressure inside the helmet.
Fig. 1.3 Many of the parts on the KMB-18 Band Fig. 1.4 The SuperLite-27 is similar to the
Mask are interchangeable with the SuperLite- SuperLite-17, yet has a completely different
17. bottom end.
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SUPERLITE-17
with the SL-27 helmet when conducting diving Flow requirements 4.5 SCFM
Breathing system man tested by USN Experimental
operations in European EC compliant countries. Maximum Operating
Depth
Diving Unit to 850 FSW and University of Pennsylvania to
1600 FSW
DANGER: Never use any aerosol propelled sprays near the face port of any
Kirby Morgan diving helmet. The propellant used in these aerosols can invisibly
damage the face port and cause it to shatter on impact from any strong blow. If the
face port fails underwater the helmet will flood and drowning may result.
1.5.7 COMMUNICATIONS
Fig. 1.7 The neck dam must be properly adjusted
The communications system is very simple in all
to fit your neck. If necessary, it may need to be
Kirby Morgan diving helmets.
trimmed to fit.
CHAPTER 2.0
OPERATING INSTRUCTIONS
Fig. 2.2 You may need to trim the head cushion Trim the neck dam until it is still snug. Trim only
to get a proper fit. 1/4 inch off the neck dam at a time. When you
are done, the neck dam must be tight enough so
2.3.2 TRIMMING THE NECK DAM that it does not leak. This may feel a bit snug out
of the water, but will be very comfortable under-
If your helmet is new, or any time you replace the water.
neck dam, it must be adjusted to fit you. New
neck dams are cone shaped and will probably be Trim the neck dam with the largest, sharpest scis-
too tight if not properly stretched and/or trimmed. sors available, in order to make as few cuts as
Try stretching the neck dam first. If this doesn’t possible. There must be no jagged edges on the
produce a proper fit, you must trim the neck dam neck dam or it may tear.
to achieve a comfortable seal.
The compressed air/gas tank must be fitted with WARNING: A standard scuba sub-
a regulator to reduce the pressure to less than 225 mersible pressure gauge must be con-
P.S.I. ambient diver pressure. The helmet cannot nected to the high pressure port on the
properly handle more pressure without modifi- first stage so that the diver can monitor
cation. The D.S.I. SuperFlow® first stage Scuba his emergency supply.
regulator (Part #305-161) is the best device for
this use. These regulators reduce the tank pres- WARNING: Never connect the
sure to approximately 145 P.S.I. Connect the first main gas supply hose from the diving
stage hose with a set of quick disconnecting lock- control station to the emergency valve
ing sleeves to the emergency valve assembly lo- assembly. If this is done there is no one
cated on the side block. Other high performance way valve protection for the diver in the
scuba regulators may also be used. event of damage to the umbilical or re-
lated equipment. The diver could be ex-
The first stage regulator must have at least two posed to a serious “squeeze”. The diver,
low pressure ports. One port is used for the con- at a minimum, must have his suit, har-
nector hose to the emergency valve and the sec- ness, and tank of emergency gas in
ond is used to install an overpressure relief valve place prior to connecting the quick dis-
(Part #200-017). If the first stage develops a leak, connect hose for the emergency supply.
the full pressure of the tank could be placed on
the low pressure hose. This could cause the hose
to burst. The overpressure relief valve will bleed Make sure the emergency valve knob (55) is
off any leak. turned off, otherwise the emergency gas supply
will be used up without the diver’s knowledge.
Once the emergency supply hose is connected,
the tank valve is turned on to pressurize the hose.
In the event of an emergency due to a loss of the
main gas supply, the emergency valve knob lo-
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SUPERLITE-17
2.7 SETTING UP TO DIVE
2.7.1 FLUSHING OUT THE UMBILICAL
Before connecting the umbilical to the helmet,
the umbilical must be flushed out to remove any
dirt, moisture, or other debris.
Pull the pull pin knob (17) out, away from the
helmet. While holding the knob out, lift the neck
clamp handle (3) up and out to release the ten-
sion on the clamp. Swing the handle forward to-
ward the front of the helmet. Slide the yoke/neck
clamp assembly backwards away from the hel-
met until the rear hinge tab (26) disengages from
the alignment sleeve (88).
Fig. 2.16 Lift the yoke/neck dam over your head. Fig. 2.18 Adjust the neck dam so that it is turned
up and out.
Fig. 2.19 Locate the end of the chin strap. Fig. 2.21 The tender can help the diver if
necessary, but the diver must be able to don
the helmet by himself.
Fig. 2.23 Tighten the chin strap. Fig. 2.26 The clamp will close easier once the
handle has passed over center.
To perform this test, the diver must be next to the Reach behind the back of the helmet with either
dive control manifold so that he may turn the air hand and lift the rear hinge tab off the alignment
on instantly. Or, he must be ready to run a hand sleeve in the back of the helmet. Reach under-
PAGE 22 Docu# 010502002
SUPERLITE-17
neath the front of the helmet and loosen the chin
strap that holds the helmet in position. Lift the
helmet over your head with both hands, one on
either side of the helmet to support its weight.
The umbilical must now be hooked to the diver’s 2.8.3 DIVER DONS HELMET
harness by means of a suitable clip that is bound
to the umbilical. Some divers and companies pre- The diver dons the helmet as per Section 2.7.5.
fer a quick release clip and others prefer a clip
that is screwed together so the diver cannot eas- 2.8.4 DIVER CHECK GAS FLOW SYSTEMS
ily remove it from his harness. The securing of The diver must check out the breathing system
the umbilical keeps the pull of the hose at the himself as the tender finishes dressing him. Op-
diver’s harness and not on the helmet. erate the defogger valve, the demand regulator,
and the purge button to assure yourself of proper
WARNING: Never dive without at-
operation before entering the water.
taching the umbilical to some type of
harness or clip on the diver’s body. 2.8.5 COMMUNICATIONS CHECK
Never allow the umbilical to pull on the
helmet directly, or the diver could suf- The communications system, sending and receiv-
fer a neck injury. ing, must be checked at this point.
2.8.6 DIVER READY
The diver must report to the surface immediately If breathing becomes difficult, adjust the regula-
after the entry. It is a good policy to descend 10 tor adjustment knob for easier breathing. If the
or 20 feet, pause to check in with the surface, then problem continues, press the purge button in the
descend to the job. If a bell is being used, after regulator cover. If a surge of gas does not flow
the bell is at depth, the diver enters the water and with this action, open the defogger (free flow
pauses for a short time outside the trunk until he valve) knob. Return to the diving station.
is sure all systems are operating properly.
2.9.3 GAS FLOW STOPS
During the descent the communications must be
checked again. It may be necessary to readjust A stop of flow in the demand regulator system
the regulator by means of the adjustment knob usually indicates the main gas supply has stopped.
(120) during descent. A very slight steady flow is The diver must first open the emergency valve
the best position for breathing air. For mixed gas, by turning the knob. If there is still no flow from
the regulator should be adjusted for maximum the demand regulator, the defogger valve must
ease of breathing, just short of having the regula- be opened. Keep in mind that if the defogger
tor free flow. valve is left open, the bail-out bottle will drain
very quickly, particularly if the diver is deep.
Once at the surface, or inside the bell, the diver Reach up with your left hand and pull out on the
may remove the helmet if needed. Never ditch pull pin knob (17) on the latch catch assembly.
the helmet underwater unless conditions abso- At the same time, grab the handle on the neck
lutely require that. clamp assembly (7) with your right hand, lift it
up and pull outwards away from the helmet, until
DANGER: Ditching the helmet un- the handle is in front of your face. This action
derwater must be avoided. If the diver will break the seal of the neck dam around the
ditches the helmet underwater he will base of the helmet and the neck dam will fall away
not be able to see. In many instances, from the bottom of the helmet.
even if the air supply is interrupted, top-
side will be able to get it back on line
quickly. Do not ditch the helmet under-
water unless you are completely out of
breathing gas and it is impossible to
return to the surface due to entangle-
ment of your equipment or similar cir-
cumstances.
SECTION 3.0
TROUBLESHOOTING
3.1 GENERAL
The SuperLite-17 is a highly reliable diving helmet which should not malfunction if proper preventa-
tive maintenance procedures are followed. Most problems encountered in using the helmet can be
easily remedied. The following information covers most potential operating difficulties.
Communications incorrectly
Switch terminal wires.
hooked up.
Plug into terminals.
Communications not hooked up.
Disassemble, clean,
Valve (58) will not flow gas. Foreign matter in valve.
reassemble.
SECTION 4.0
NOTES
SECTION 5.0
GENERAL PREVENTATIVE MAINTENANCE
5.1 INTRODUCTION
This section covers the preventative mainte-
nance necessary on the SuperLite-17 diver’s
helmet. A helmet that is kept clean and in
good repair will offer far better service to
the user. This helmet is designed for easy
access to all areas for proper inspection and
servicing. Numbers appearing in parenthe-
ses below are “location” numbers that are
used in the blow apart illustration at the rear
of this manual.
LUBRICATION:
Silicone Grease
Fig. 5.7 Remove the earphone covers so the DANGER: Never patch a torn or
earphones can dry. punctured neck dam. If the patch comes
off underwater the helmet could flood
and/or the demand regulator assembly
may not function properly. A damaged
neck dam must be replaced.
CHAPTER 6
BREATHING SYSTEM MAINTENANCE AND REPAIRS
6.1 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 on the SuperLite-17B, the hose assem-
bly on the SuperLite-17A, the demand regulator,
and the oral/nasal mask.
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)
adapter
seat
wiper o-ring
o-ring
poppet
spring
valve body
o-ring
7) Place the new o-ring (59) on the end of the one 2) Using two wrenches, hold the nut at the regu-
way valve assembly and reinstall the valve as- lator end of the bent tube assembly with the first
sembly in the side block (43a/b). Tighten to 240 wrench. With the other wrench, loosen the jam
inch lbs. with a torque wrench . nut (131b) by turning the wrench DOWN.
6.3 SIDE BLOCK ASSEMBLY 3) Unthread the nut until it comes free, then pull
the bent tube assembly straight out of the regula-
6.3.1 GENERAL tor inlet nipple (132b).
Tools Required:
11/16 inch Open End Attachment on Torque
Wrench
7/8 inch Open End Wrench Attachment on Torque
Wrench
7/16 Inch Open End Wrench Fig.6.4 On the SuperLite-17B, you must
1/4 inch Flat Blade Stubby Screwdriver disconnect the bent tube to remove the side block.
2) Loosen the nut on the end of the hose assem- 1) Removal of the side block assembly requires
bly (45a) and completely disconnect it from the removing the air train (99).
inlet nipple.
2) Remove the nut (101) and washer (100), then
the air train.
If a new side block is being installed, make sure 5) Slip the air train (99) over the stud. Align the
it aligns correctly in the holes of the helmet shell air train with the upper edge of the view port open-
before applying RTV silicone sealant. ing in the helmet shell.
1) A generous application of silicone sealant must 6) Place the washer (100) on the stud and tighten
be applied to the side block (43a/b) prior to in- the nut (101) until the washer lays flush on the
stallation on the helmet shell. Use only Dow air train. DO NOT OVERTIGHTEN.
Corning® RTV 732 Multi Purpose sealant. Care
must be taken to avoid sealant entering the air 7) Test the side block prior to diving to ensure
opening in the side block. Be sure to remove all that no silicone sealant is blocking the air flow to
excess silicone sealant before it sets up. Lacquer the helmet. If it is, it must be cleaned out prior to
thinner can be used to dissolve unset sealant. diving.
Tools Required:
3/8 inch Slotted Flat Blade Screwdriver
13/16 inch Open End Attachment on Torque
Wrench
seat assy.
emergency valve handle
bonnet
valve stem
4) Lubricate the new o-ring (37) and install on 6) Tighten the bonnet with a torque wrench to
the bonnet (36). 100 inch lbs.
Tools Required:
11/16 inch Open End Attachment on Torque
Wrench
3/8 inch Slotted Flat Blade Screwdriver
1 inch Open End Attachment on Torque Wrench
8 inch Adjustable Wrench
Fig. 6.19 Remove the nut and spring from the Fig. 6.21 Remove the packing nut from the valve.
emergency valve.
PAGE 48 Docu# 010502002
SUPERLITE-17
2) Undo the packing nut (54). When the packing 6.5.2 CLEANING AND LUBRICATING
nut is free of the threads of the emergency valve
body (50), back out the stem (51) until it is free 1) Clean all the metal parts in a 50/50 dilute solu-
of the emergency valve body. tion of white vinegar/water. Rinse with fresh
water.
3) Remove the packing nut, packing (53), and
washer (52) from the stem. 2) Inspect the packing (53) and washer (52) for
wear and replace if necessary.
NOTE:
The emergency valve does not have to be removed
from the side block to be rebuilt.
Fig. 6.23 If you want to remove the valve body, 3) Holding these components in place on the stem,
the handle and stem must be removed first. screw the stem into the emergency valve body.
Docu# 010502002 PAGE 49
SUPERLITE-17
WARNING: A leaking emergency
valve assembly can cause the diver to
exhaust his entire emergency air supply
(bailout) without his knowledge. This may
lead the diver to mistakenly assume his
bailout supply is available when it is not.
This could lead to panic or drowning in
an emergency. Any worn component that
causes an emergency valve to leak must
be replaced.
Tools Required:
11/16 inch Open End Attachment on Torque
Wrench
7/8 inch Open End Attachment on Torque Wrench
7/8 inch Open End Wrench
The bent tube must be free of dents. If the hel- 4) Tighten the bent tube assembly onto the side
met has been used for burning jobs, carefully block (43b). See Appendix I for torque specifica-
check for erosion of the metal. Replace if neces- tions.
sary.
5) Start the regulator to bent tube mount nut onto
the inlet nipple. Run it in HAND TIGHT ONLY.
Tools Required:
1/4 inch Flat Blade Attachment on Torque Screw-
driver
Fig. 6.33 Test the regulator with a supply of 1) Remove the demand regulator clamp (125) by
breathing gas connected to either the inlet adapter removing the clamp screw (124).
or emergency valve.
2) Lift off the demand regulator cover (123) and
5) Check the exhaust valves by turning the de- diaphragm (122).
fogger control knob (34) and the emergency con-
trol knob off (55). Stand next to the manifold 3) Clean the diaphragm and check it for holes.
and turn the air supply off to the helmet. Drain
the supply hose but be sure the air is on to the 4) Inspect the interior of the demand regulator
manifold. Don the yoke/neck clamp and helmet, body (112) for foreign objects and cleanliness.
close the neck clamp assembly, and try to inhale.
If any leakage is present it could be from the regu-
lator exhaust, neck dam, or other component.
Tools Required:
3/4 inch Open End Wrench Attachment on Torque
Wrench
3/32 inch Punch
Small Block of Wood
Ball peen Hammer
Fig. 6.35 Remove the diaphragm so you can
Start at the adjustment knob end of the regulator:
inspect the interior of the regulator.
1 ) Unscrew the knob (120) until it stops and a
wrench can be placed on the nut (119).
adjustment knob
regulator cover
exhaust valve springs
inlet valve
-N
SI
AV
D
Y
350 R
or
t
e g ula
clamp
roller lever diaphragm
4) Remove the washer (117) and o-ring (118). 1) Place the piston (113) back in the regulator
adjustment tube, followed by the spring set (114),
5) Turn the helmet on its side, side block at the and spacer (115).
top, and shake out the spacer (115), spring set
(114), and piston (113). 2) Place the washer (95) and o-ring (96) on the
shaft (94).
6) Clean and lubricate generously with silicone
grease. 3) Slip the packing nut (119) over the shaft fol-
lowed by the adjustment knob (120).
Docu# 010502002 PAGE 57
SUPERLITE-17
4) Drive the pin (121) back into place until it is 17A, you can just disconnect the hose assembly
flush with the surface of the adjustment knob. from the regulator, leaving the upper end of the
hose connected to the side block (43a).
5) Screw the shaft back into the regulator body
(116). 2) Remove the whisker (139) from the port re-
tainer (141) by removing the screws (111). Take
6) Thread the packing nut onto the regulator body care not to lose the spacers (109) or kidney plates
and tighten with a 3/4 inch torque wrench. (110).
Tools Required:
1 3/8 inch Socket on Torque Wrench
1/4 inch Flat Blade Attachment on Torque Screw-
driver
11/16 Open End Attachment on Torque Wrench
13/16 Open End Attachment on Torque Wrench
7/8 inch Open End Attachment on Torque Wrench
7/8 inch Open End Wrench
Fig. 6.40 To remove the regulator, the whisker Fig. 6.42 The regulator mount nut secures the
must be released at the face port. regulator to the helmet.
PAGE 58 Docu# 010502002
SUPERLITE-17
4) The packing nut (119) is now exposed enough
to use a wrench on it for removal. As the nut is
backed off, unscrew the knob, also.
2) Lift the cover (123) off and take out the dia-
phragm (122).
3) Adjustment knob (120) removal is started by Fig. 6.44 The castle wrench is used to prevent the
unscrewing the adjustment knob until it stops. inlet valve from turning.
Docu# 010502002 PAGE 59
SUPERLITE-17
10) Remove the nut completely. The DSI socket 6.8.8 CLEANING AND INSPECTION OF
wrench can be inserted into the adjustment tube DEMAND REGULATOR PARTS
for removal of the nut.
Clean all metal parts in a sonic cleaner or in white
11) Tilt the regulator and drop out the inlet valve, vinegar and blow off with air. Inspect all parts
spring (135), and washer (136). carefully. Replace any that are worn or damaged
as well as all that are supplied in the repair kit.
12) The spacer (127), lever (128), and washer
(129) will now fall out of the regulator body. All regulator parts must be free of damage, dirt,
and corrosion. All rubber components must be in
6.8.7 INSPECTION OF DEMAND excellent condition.
REGULATOR PARTS
6.8.9 REASSEMBLY OF THE DEMAND
After the regulator has been disassembled, inspect REGULATOR
the parts. If the parts show signs of wear or dete-
rioration they must be replaced, even if it is prior 1) Install the new exhaust valve (137) into the
to the recommended replacement interval. regulator and trim off any excess stem that may
interfere with the movement of the lever or inlet
1) Inlet valve: Check condition of rubber for wear valve.
and/or deep grooves.
2) Install the spring (135) and washer (136) on
2) Diaphragm: Check to determine if rubber has the inlet valve.
separated from the metal part. Inspect for cracks,
pin holes, and pinching of outer edges. 3) Press the head of the inlet valve (134) into the
castle wrench (DSI Part #525-618. With the inlet
4) Push in on the castle wrench and depress the 9) Lightly lubricate the piston (113) and spacer
inlet valve so the stem extends into the interior of (115). Install the piston, spring set (114) and
the regulator body. Place the washer (129) and spacer into the adjustment tube of the regulator
the spacer (127) over the end of the inlet valve body as shown in the blow-apart drawing.
stem. The washer and spacer may be placed in
the recess in the inside of the regulator body (112) 10) If you have disassembled the adjustment knob
before inserting the inlet valve. assembly (138c), next slide the washer (117) and
o-ring (118) onto the adjustment shaft (116).
5) Place the nut (126) into the socket of the socket
wrench from DSI regulator tool kit and insert it 11) Slide the packing nut (119) onto the adjust-
through the adjustment shaft tube. With the inlet ment shaft, then slip the knob (120) onto the end
valve depressed, run the nut onto the inlet valve of the shaft. Hold the shaft and rotate the knob
stem about 2 turns, leaving enough slack to al- until the pin holes line up. Use the inlet valve
low installation of the lever (128). With the inlet holder from the regulator tool kit to accurately
valve depressed the washer and spacer must be align these holes.
loose on the inlet valve stem.
12) Install the retaining pin (121) by tapping it in
6) The lever is installed next. The lever legs with a light hammer until it is flush.
MUST be parallel to each other. Check them with
a straight edge and align them if necessary by 13) Lubricate the threads lightly, then thread the
carefully bending them with pliers. Now, with the adjustment shaft into the tube until the packing
inlet valve depressed insert the lever legs between nut can be started. Tighten the packing nut to 40
the washer (129) and spacer (127). inch pounds. Make sure that the adjustment knob
(98) is run in simultaneously.
7) Hold the inlet valve in position. Now tighten
the nut (126) until two threads are visible past 14) Check the adjustment knob for free rotation.
the nut.
15) Stretch the exhaust whisker (139) onto the
8) While holding the lever down, install the inlet exhaust flange of the regulator.
nipple (130a or 132b) with it’s o-ring (133) into
16) Mount the regulator to the mask or helmet.
Lubricate and install the sealing o-ring (81) and
thread on the regulator mount nut (82).
17) If you have the 17B, install the bent tube as-
sembly (47b) before tightening the regulator
mount nut. Lubricate the o-ring (46b) on the bent
tube assembly. Slide the o-ring end of the bent
tube assembly into the regulator inlet nipple
(132b) until the side block end is aligned with
the threads for the bent tube mount nut. Insure
that the Teflon o-ring is in place and tighten the
mount nut to100 inch pounds. If you have the
17A, you can attach the hose assembly (46a) last.
Fig. 6.47 The inlet side of the demand regulator.
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SUPERLITE-17
6.8.10 TUNING THE REGULATOR
18) Now tighten the regulator mount nut (82) to 5) Insert the inlet valve holding tool into the bal-
100 inch pounds. Thread the large nut on the bent ance hole on the inlet tube. Push forward and
tube assembly onto the inlet nipple. Run this nut left on the tool to stop the inlet valve (134) stem
on until it just bottoms on the shoulder on the from turning. Adjust the nut (126) until there is
bent tube. Do not tighten further. Using two 1/16 to l/8 of an inch of free play at the end of the
wrenches, hold the large nut on the regulator end lever (128).
of the bent tube and tighten the jam nut (131b) to
100 inch pounds. 6) Remove the inlet valve holder tool.
19) Attach the whisker (139) to each side of the 7) Place the diaphragm and cover in place, de-
face port retainer (141) using the screws (111), pressing the cover tightly to simulate a properly
plates (110) and spacers (109). Carefully torque tightened clamp.
these screws to 12 inch pounds.
8) Depress the purge button in the center of the
20) Adjust the regulator following instructions in cover.
Section 6.8.10. Adjustment instructions are also
included in the regulator tool kit. 9) There must be l/8th of an inch of free travel
before the button comes in contact with the dia-
21) Install the diaphragm (122), cover (123), phragm. The lever must now be adjusted to this
clamp (125) and screw (124). Torque the screw proper height if it is not already correct. The nut
to 8 inch pounds. can be loosened no more than l/8th of a turn to
lower the lever height. The lever must be bent if
22) If you have the 17A, connect the hose assem- more adjustment is necessary.
bly (46a) to the inlet nipple. Tighten the nut on
the hose while holding the inlet nipple (130a), 10) To bend the lever up, grip the lever from the
with a second wrench, to prevent it from turning. side with a pair of long nosed pliers and bend the
roller end up with your thumb. NOTE: Be very
22) Check the regulator for proper operation and careful to not place undo stress on the lower arms
fine tune the adjustment if necessary. of the lever as this will disfigure the lower blades
and cause spongy operation.
IMPORTANT NOTES ON REGULATOR Fig. 6.49 The inlet valve holder is inserted in the
ADJUSTMENT: balance hole on the inlet tube.
4) Normally, if the regulator leaks breathing gas, Fig. 6.50 To bend the lever up, use a pair of pliers.
the nut (126) is too tight, and must be loosened
until the lever has 1/8th of an inch of freedom at sealing surface. If the leak continues, the regula-
the end. tor must be disassembled, thoroughly cleaned,
inspected, lubricated, and reassembled.
5) If the regulator continues to leak either the in-
let valve (134) must be changed or the inlet nipple
(132b or 130a) must be inspected for a damaged
1) Screw in the adjustment knob (120) all the way. 12) Press the purge button in the cover. There must
be 1/8 inch travel before the purge button touches
2) Pressurize the helmet to approximately 150 the diaphragm. If there is no travel, or more than
P.S.I. If the regulator steady flows, make sure the 1/8 inch travel in the purge button, it may be nec-
adjustment knob is turned clockwise all the way essary to bend the lever to its proper height (see
in. Make sure the supply pressure is not too high Section 6.8.10). If the purge button seems to be
(over 225 P.S.I.). After checking the knob and the correct, proceed with assembly.
pressure, if the regulator continues to steady flow,
the nut (126) is too tight and must be loosened. 13) Install the clamp (125) and clamp screw (124).
Tighten the screw.
3) Turn off the breathing gas supply. The system
must bleed off. You may need to press the purge 14) Again, press on the purge button in the cover.
button or open the free flow valve to get the sys- It must have 1/16 inch minimum and 1/8 inch
tem to drain completely.
PAGE 64 Docu# 010502002
SUPERLITE-17
maximum free travel before it contacts the dia-
phragm. If there is more than 1/8 inch travel, the
lever must be bent upward . If the button has only
slight or no free travel, the lever must be bent
down (see Section 6.8.10).
12) If the purge button travel is correct, the ad- 3) Back the adjustment knob (120) all the way
justment is complete. out.
6.8.13 REGULATOR HAS LOW OR NO 4) Install the inlet valve holder into the lower
FLOW WHEN PRESSURIZED equalizing hole of the regulator and press up or
down to prevent rotation.
Tools Required:
DSI Regulator Adjustment Tools, 5) Run the adjustment knob all the way in.
DSI Part #525-620 6) Pressurize the system to about 150 P.S.I. There
1/4 inch Flat Blade Attachment on Torque Screw- must be no steady flow.
driver
11) Press the purge button in the cover. There must One method to check this is for the diver to place
be 1/16 inch to 1/8 inch travel before the purge the demand regulator above the neck dam by look-
button pushes the diaphragm against the lever. A ing up. The steady flow will stop and water may
flow of gas will start when the lever is depressed. leak in through the neck dam leak.
If there is no travel, or more than 1/8 inch travel
in the purge button, it may be necessary to bend
the lever to its proper height by the method ex-
plained in Section 6.8.10. If the purge button
travel seems to be correct, proceed with assem-
bly.
1) Remove the nose block device (86) first. See DANGER: The oral/nasal valve
Section7.3. must be replaced correctly to provide gas
flow in the proper direction. The flow
2) Remove the oral/nasal microphone (73). through the valve must be from the inte-
rior of the helmet into the oral nasal mask.
3) The oral/nasal mask can then be pulled off the This will allow the diver to breathe the gas
regulator mount nut (82). It is held on by a snap from the defogger valve freely, yet help
fit. to reduce carbon dioxide inside the hel-
met. If the valve is not replaced properly
this could make it difficult to breathe the
gas supplied by the defogger and expose
the diver to an excess of carbon dioxide.
This could lead to exhaustion and black-
out.
Fig. 6.54 Once you have removed the nose block Fig. 6.55 If the valve in the oral/nasal is worn, it
device, you can remove the oral/nasal mask. must be replaced.
Tools Required:
1/4 inch Flat Blade Attachment on Torque Screw-
driver
6.9.3 ORAL/NASAL REPLACEMENT 2) The whisker is also held on each side of the
helmet at the port retainer (141). Two screws
1) Snap the oral/nasal over the regulator mount (111), stand off spacers (109) and one plate (110)
nut (82). hold each side. Complete removal of the whisker
is done by removing these screws, spacers and
2) Reinstall the microphone (73). plate. Take care not to lose the four spacers.
o-ring
port
whisker
6.11.2 MAIN EXHAUST VALVE REPLACEMENT Fig. 6.60 The main exhaust valve must be in good
condition. If not, replace it immediately.
1) The rubber main exhaust valve (150) installs
by inserting the center stem through the main
2) Carefully pry the main exhaust body (149)
exhaust body (149), and then pulling from inside
away from the helmet shell (93).
the helmet shell (58) until it snaps into place.
3) Clean off any silicone sealant on the main
2) Replace the main exhaust cover.
exhaust body or helmet shell.
6.11.3 MAIN EXHAUST BODY REMOVAL
4) Remove the cover and rubber exhaust valve if
Tools Required: they need replacement as per Section 6.11.1.
1/4 inch Flat Blade Attachment on Torque
6.11.4 MAIN EXHAUST BODY REPLACEMENT
Screwdriver
1) Apply silicone sealant to the base of the ex-
1) Unscrew the 3 screws (148) inside the helmet
haust body (149). Take care not to block the open-
shell (92).
ing for the main exhaust valve (150).
CHAPTER 7.0
CORRECTIVE MAINTENANCE
Fig. 7.1 Use padded pliers to remove the nose Fig. 7.2 Reinstall the knob and tighten it
block knob. securely.
7.7.1 GENERAL
The face port (77), or viewing lens, is made
of plastic. Small scratches on the exterior
are not important as they tend to disappear
underwater. However, the faceport is easily
replaced by removing the port retainer (78)
and dropping in a new faceport.
Fig. 7.14 The port O-ring is made from a special Fig. 7.15 The kidney plate screws, like all screws
durometer rubber. that go through the port retainer, must be tightened
with a torque screwdriver.
PAGE 80 Docu# 010502002
SUPERLITE-17
and in extreme instances to flooding of the hel-
met. The testing procedure is designed to locate WARNING: The material used In the
any inserts that have been damaged and need face port (113) Is very strong. However,
replacing. Any replacement/repair of inserts certain chemicals will attack the port and
and the surrounding fiberglass port area must weaken It. Some solvents used for
be carried out by an authorized DSI trained grease removal will also attack the port .
representative that has trained specifically in Use only mild detergents or organic soaps
thread insert repair/replacement. Any other re- to clean the face port. Never allow
pair/replacement is not authorized by DSI. overspray of silicone lubricant to get on
the face port. Although the silicone's lu-
7) Install the nose block device (51) from the bricant is non-injurious, the propellent is
interior of the oral/nasal mask(50) and out usually Freon (chlorinated hydrocarbon)
through the lower packing fitting on the port that will damage the port. This could
retainer (78). cause the face port to fail after a minor
impact.
8) Slide the two lubricated o-rings (82) onto
the shaft of the nose block device (51).
7.7.4 SPECIAL NOTE REGARDING PORTS
9) The packing nut (84) is threaded into
place followed by the nose block device Note that there are two different face ports
knob (85). available for DSI helmets and masks. One port
specifically fits the SuperLite-17, the SuperLite-
10) Tighten the packing nut (84) until some 27, and the KMB 18. One port only fits the
resistance is felt when the nose block device KMB 28 Band Mask. These two ports are not
knob is pushed in and out. Tighten the nut interchangeable. The face port for the SuperLite-
until the shaft (51) will no longer slide, then 17, the SuperLite-27, and the KMB 18 is Part
back the nut off until the shaft begins to slide #520-004. The face port for the KMB 28 Band
again. Mask only is Part #520-128.
11) If this nut is too tight the nose block DANGER: The face port for the
device cannot slide in and out. SuperLite-17 and KMB 28 are not inter-
changeable. Do not attempt to use a face
12) The nose block device knob (85) should port from a KMB 28 in a SuperLite-17.
be tightened with a padded pair of pliers, Although the port will fit into the helmet
while holding the nose block pad on the shell, it will not seal properly. This will
inside of the helmet. lead to continuous leakage of the helmet
and could cause a rapid depletion of the
diver’s breathing gas as he attempts to
clear the helmet.
To service the earphones, remove the head 4) If the rubber covers are not good, replace
cushion (1) from the helmet first by releasing them also.
the snaps inside the helmet. The earphones (71,
7.8.3 Microphone Removal and
72) can be carefully pulled out of the helmet
(92) by lifting the earphone retainers (147) and Replacement
sliding the earphones out from underneath them. Tools Required:
1/8 inch Flat Blade Screwdriver
1) The rubber front cover is removed from the
earphone first, the rear cover is next removed. The entire microphone (73) is replaced the
This exposes the plastic “cookie” that protects same as the earphones by removing the wire
the earphone and the earphone cone itself. lugs from the communications posts (154) and
replacing the entire unit.
The earphones may be replaced individually if Fig. 7.18 If your helmet is equipped with the
needed, however, if one is “bad”, the other terminal block, this is where the earphones and
earphone will probably need to be replaced microphone will be connected inside the helmet.
soon, too.
7.8.6.1 Communications Post Removal Fig. 7.22 RTV -silicone sealant- is used to seal the
binding posts on the helmet.
Tools Required;
3/8 inch Open End Wrench DANGER: Do not breathe the
fumes from uncured silicone sealant.
1) Disconnect the communications set (74) as These fumes are dangerous and can
per Sections 6.83 and 6.84. cause unconsciousness. They can also
cause long term damage to body tissue.
2) Remove the nut (145) and washer (146). Read and follow all precautions listed
on the silicone sealant tube.
3) Pull the communications post (154) away
from the helmet shell (92). 3) Insert the communications posts (154) into
the helmet shell (92).
7.8.6.2 Communications Post Replacement
4) Install the washer (146) followed by the nut
1) Clean off all the old RTV silicone sealant (145). Tighten the nut to 15 inch pounds of
from the helmet shell (92) and communications torque.
post (154).
5) Wipe off all the excess silicone sealant from
2) Apply fresh RTV to the communications the helmet shell (92).
post(s) (154).
7.9.1 Yoke
1) Unscrew the three screws (15) that fasten the Fig. 7.23 Use Loctite® on the screws that connect
latch catch assembly (22) to the yoke (31). the latch catch to the yoke.
3) Apply Loctite® to the shaft and screw the Adjustments must be made with the yoke/neck
knob onto the shaft. clamp assembly separated from the helmet, but
must be tested on the helmet.
4) Align the hole in the knob with the hole in the
1) Loosen the nut (6) and adjust the position of
the nut (4) as necessary.
Tools Required:
7/16 inch wrench
Fig. 7.31 Locate the large hole in the neck dam. Fig. 7.34 Insert the adjustment stud through the
adjustment block and thread the lock nut onto the
stud.
Fig. 7.33 Feed the small hole in the neck dam over
the adjustment block.
NOTES
CHAPTER 8
ACCESSORIES
8.1 INTRODUCTION
This section provides the manufacturer’s ad- 5) To install the rubber regulator cover, slide
vice on how to install DSI accessories in- it over the bent tube assembly and stretch it
cluding the hot water shroud, low pressure over the regulator adjustment knob.
inflator hoses, and the weld lens assembly.
Tools Required:
1/4 inch Flat Blade Screwdriver
7/8 inch open end wrench
7/8 inch Open End Attachment on Torque
Wrench
11/16 inch Open End Attachment on Torque
Wrench
Fig. 8.3 Slide one of the PVC pieces over the Fig. 8.4 Place the corrugated tube over the bent
bent tube and insert it into the regulator shroud. tube.
Tools Required:
5/32 inch Allen Wrench Attachment on
Torque Wrench
Fig. 8.8 Use a hex key to remove the plug. Fig. 8.10 Completed installation of a dry suit
inflator hose.
PAGE 96 Docu# 010502002
SUPERLITE-17
3) Tighten fitting to the specifications pro-
vided by the dry suit manufacturer. Do not
overtighten.
Fig. 8.13 Tighten the screws to hold the weld lens One end of the connector is designed to be
assembly securely. attached to the emergency valve assembly
(27), while the other end of the connector is
designed to attach to any of the standard low
pressure ports on the DSI SuperFlow first
stage regulator (or any high performance
regulator) used for the bail-out supply.
Caution - Warning
These assemblies are designed to provide
visual protection only. We highly recommend
that extreme caution be exercised by all divers,
regardless of helmet or mask used, to avoid the Fig. 8.14 Using the quick disconnect.
possibility of underwater explosions when cut-
ting or welding. It cannot be over stressed that
any underwater explosion can result in the
injury or death of the diver!
Fig. 8.19 Attach the double exhaust body to the Fig. 8.20 Position the regulator on the helmet.
helmet using the screws.
PAGE 100 Docu# 010502002
SUPERLITE-17
NOTES
APPENDIX I
TORQUE SPECIFICATIONS FOR SUPERLITE-17A/B