Kirby Morgan EXO original Manuel

Operations & Maintenance Manual

for the EXO Original, EXO Standard

and EXO Balanced Regulator Full Face Mask.

Diving Systems International, Inc.

425 Garden Street

Santa Barbara, Ca. 93101, USA

Telephone (805)965-8538, FAX (805)966-5761

Manual prepared by: Diving Systems International, Inc.

EXO-26 is a registered trademark of Diving Systems International, Inc

DSI Part #: 100-030

Document # 001026001

EXO Full Face Mask Manual

Document # 001026001

WARNING: Diese Mitteilung ist wichtig. Bitte übersetzen lassen.

WARNING: Ceci est important. Veuillez traduire.

WARNING: Quest è un avviso importante. Tradurlo.

WARNING: Este es un aviso importante. Sirvase mandario traducir.

WARNING: Este é um aviso importante. Queira mandá-lo traduzir.

Definitions of Signal Words Used in this Manual

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.

DANGER: This word indicates an imminently hazardous situation, which if not

avoided, will result in death or serious injury.

WARNING: This word indicates a potentially hazardous situation which, if not

avoided, could result in death or serious injury.

CAUTION: This word indicates a potentially hazardous situation which, if not

avoided, may result in minor or moderate injury. It may also be used to alert against

unsafe practices.

If English is not your native language and you have any difficulty understanding the language

of any warnings as they appear in the manual, please have them translated.

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.

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EXO Full Face Mask Manual

Document # 001006001

DANGER: Diving is a life threatening occupation. Even if you do everything right

you can still be killed or injured. None of the models of Kirby Morgan Band Mask can

prevent accidents, injuries or death due to improper training, lack of health, improper

supervision, improper job requirements, improper maintenance or acts of God.

IMPORTANT SAFETY INFORMATION

This EXO Full Face Mask is intended for use by trained divers who have successfully

completed a recognized training course in the use of a full face mask, and if used in the surface

supplied mode, an approved surface supplied diving course.

WARNING: Follow all the instructions in this manual carefully and heed all safety

precautions. Improper use of this diving mask could result in serious injury or death.

DANGER: Diving Systems International (DSI) warns all divers who use the EXO

Full Face Mask to use only DSI original spare parts from a DSI authorized dealer.

Although other parts, O-rings and fittings may not to 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.

DANGER: Diving in an environment that is chemically, biologically, or radiologi-

cally contaminated is extremely hazardous. Although the EXO Full Face Mask may be

adapted for use in some contaminated environments, special training, equipment, and

procedures are necessary. Do not dive in a contaminated environment unless you have

been thoroughly trained and equipped for this type of diving.

Read this manual before using or maintaining the mask, even if you have experience with other

diving masks. If you have purchased the mask 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 mask to another diver, be sure this manual

accompanies the mask and that the person reads and understands the manual.

WARNING: DO NOT dive this mask in water containing high concentrations of

petroleum based chemicals. DO NOT use any chemical locking liquids anywhere on

the mask. DO NOT use any type of aerosol sprays on the mask. These chemicals can

attack, damage, and compromise the structural integrity of the plastic parts on the

mask . Clean the mask using only mild soap and water.

EXO Full Face Mask Manual

Document # 001026001

WARNING: This mask 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.

This manual is supplied to the original purchaser of this mask. If you have any questions about

the use of the mask or you need another copy of this manual, Part Number 100-030, contact

Diving Systems International. If you have any questions regarding the use, maintenance, or

operation of this mask, contact Diving Systems International at (805) 965-8538.

DANGER: The EXO Full Face Mask is not equipped or lubricated for oxygen

service. Using this mask with oxygen percentages above 23.5% by volume may lead to

explosions that can result in serious injury or death.

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.

EXO Full Face Mask Manual

Document # 001026001

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 the date of purchase. This warranty does not cover rubber parts or

communications components.

Should any part be defective, contact your nearest authorized DSI dealer. If there

is no dealer in your area, contact DSI directly at (805) 965-8538 or FAX (805)

966-5761. You must have a return authorization from DSI. Upon approval from

DSI, return the defective part, freight prepaid to the DSI plant. The part will be

repaired or replaced at no charge as deemed necessary by DSI.

This warranty becomes null and void if:

1) Your completed warranty card is not received by DSI within ten (10) days

of purchase date.

2) The Warranty Card is not completely filled our or information on the

warranty card is falsified.

3) The product has not been properly serviced and maintained according to the

appropriate DSI manual and the use of Kirby Morgan Genuine replacement

parts.

4) Unauthorized modifications have been made to the product.

5) The product has been abused or subjected to conditions which are unusual or

exceed the product's intended service.

EXO Full Face Mask Manual

Document # 001026001

Contents

A BRIEF HISTORY ....................................................................................................................................... 1

CHAPTER 1 GENERAL INFORMATION .............................................................................................. 3

1.1 INTRODUCTION ................................................................................................................................... 3

1.2 SPECIFICATIONS .................................................................................................................................. 4

1.3 DESIGN PURPOSE ................................................................................................................................ 4

1.4 ACCESSORIES ...................................................................................................................................... 6

1.4.1 Hoods ................................................................................................................................................. 6

1.4.2 Mask Carrying Bag............................................................................................................................ 6

1.4.3 Communications ................................................................................................................................ 6

1.4.4 Low Pressure High Flow Hose .......................................................................................................... 7

1.4.5 Manifold Block .................................................................................................................................. 7

1.4.6 Tool Kit & Pouch ............................................................................................................................... 7

1.4.7 Regulator Mount Nut Tools ............................................................................................................... 7

1.4.8 Face Cushion Kit ............................................................................................................................... 7

1.4.9 Equalizing Device, EXO Original only ............................................................................................. 8

1.4.10 EXO Head Protector .............................................................................................................................. 8

1.4.11 Air Inlet Swivel ..................................................................................................................................... 8

1.4.12 Over Pressure Relief Valve .................................................................................................................... 8

CHAPTER 2 OPERATING INSTRUCTIONS ........................................................................................ 9

2.1 INTRODUCTION ................................................................................................................................... 9

2.2 FIRST USE AND PRE-DIVE SET UP ................................................................................................... 9

2.3 PRE DRESS-IN PROCEDURE .............................................................................................................. 9

2.4 VISUAL INSPECTION .......................................................................................................................... 9

2.5 CLEAN FACE PORT .............................................................................................................................. 9

2.6 ADJUSTING THE EQUALIZER, EXO STANDARD OR BR ............................................................ 10

2.7 CHECKING REGULATOR FUNCTIONS

AND PREPARING THE EXO FOR USE IN THE SCUBA MODE. .................................................. 10

2.8 WIRELESS COMMUNICATIONS ...................................................................................................... 11

2.9 USING THE EXO IN THE SURFACE SUPPLIED MODE ................................................................ 11

2.10 TESTING THE MANIFOLD BLOCK ................................................................................................. 12

2.11 DIVER'S HARNESS ............................................................................................................................. 13

2.12 INSTALLING THE MANIFOLD BLOCK ON THE DIVER'S HARNESS ....................................... 14

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EXO Full Face Mask Manual

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2.13 BAILOUT BOTTLE (EMERGENCY AIR SUPPLY) .......................................................................... 14

2.14 FIRST STAGE REGULATOR .............................................................................................................. 14

2.15 OVER PRESSURE RELIEF VALVE ................................................................................................... 15

2.16 CONNECTING THE HOSES TO THE MANIFOLD BLOCK ........................................................... 15

2.17 HARD WIRE COMMUNICATIONS ................................................................................................... 16

2.18 RECOMMENDATIONS FOR DONNING AND REMOVING .......................................................... 16

2.18.1 Donning ........................................................................................................................................... 17

2.18.2 Removal .......................................................................................................................................... 17

2.19 PROPER HOOD FIT ............................................................................................................................ 18

CHAPTER 3 IN WATER OPERATIONS ............................................................................................... 19

3.1 INTRODUCTION ................................................................................................................................. 19

3.2 WATER ENTRY .................................................................................................................................... 19

3.3 REGULATOR ADJUSTMENT ............................................................................................................ 19

3.4 SPIDER ADJUSTMENT ...................................................................................................................... 20

3.5 PURGING THE MASK ........................................................................................................................ 20

CHAPTER 4 POST DIVE PROCEDURES ............................................................................................ 21

4.1 POST DIVE RINSE .............................................................................................................................. 21

4.2 REASSEMBLING THE MASK AFTER CLEANING ........................................................................ 21

CHAPTER 5 REGULATOR MAINTENANCE ..................................................................................... 23

5.1 GENERAL INFORMATION ................................................................................................................ 23

5.2 ORIGINAL AND STANDARD EXO REGULATOR DISASSEMBLY .............................................. 23

5.3 ORIGINAL AND STANDARD EXO REGULATOR REBUILD ........................................................ 26

5.4 EXO BALANCED REGULATOR DISASSEMBLY ........................................................................... 27

5.5 EXO BALANCED REGULATOR REASSEMBLY ............................................................................ 29

5.6 REGULATOR ASSEMBLY REMOVAL AND INSTALLATION ....................................................... 31

5.6.1 Regulator Assembly Removal .......................................................................................................... 31

5.6.2 Regulator Assembly Installation ....................................................................................................... 31

5.7 EXO REGULATOR ADJUSTMENT ................................................................................................... 33

5.8 LENS REPLACEMENT ....................................................................................................................... 33

5.8.1 Lens Removal ................................................................................................................................. 33

5.8.2 Lens Installation ............................................................................................................................. 34

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EXO Full Face Mask Manual

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5.9 BUCKLE REPLACEMENT ................................................................................................................. 36

5.9.1 Buckle Removal ............................................................................................................................. 36

5.9.2 Buckle Installation .......................................................................................................................... 37

5.10 REPLACING THE FACE SEAL OR FRAME ..................................................................................... 38

5.10.1 Face Seal Removal ......................................................................................................................... 38

5.10.2 Face Seal Installation ...................................................................................................................... 39

5.11 MANIFOLD BLOCK MAINTENANCE ........................................................................................... 39

5.11.1 Daily ............................................................................................................................................. 39

5.11.2 Post Dive Procedures .................................................................................................................... 39

5.11.3 Annual Overhaul ........................................................................................................................... 40

5.11.3.1 Disassembly ........................................................................................................................... 40

5.11.3.2 Disassembly & cleaning of the one way valve ...................................................................... 40

5.11.3.3 Reassembly of the one way valve .......................................................................................... 41

5.11.3.4 Disassembly of the emergency valve..................................................................................... 41

5.11.3.5 Cleaning & Lubricating of the emergency valve ................................................................... 42

5.11.3.6 Reassembly of the emergency valve ...................................................................................... 42

5.11.3.7 Reassembly of the Manifold Block ....................................................................................... 43

CHAPTER 6 COMMUNICATIONS ....................................................................................................... 45

6.1 BARE WIRE BINDING POSTS .......................................................................................................... 45

6.2 WATERPROOF CONNECTOR (WPC) ...............................................................................................45

6.3 WIRELESS COMMUNICATIONS ...................................................................................................... 46

6.4 REMOVING THE COMMUNICATIONS MODULE ......................................................................... 47

6.5 INSTALLING THE COMMUNICATIONS MODULE ....................................................................... 48

6.6 EARPHONE AND/OR MICROPHONE REMOVAL .......................................................................... 49

6.7 EARPHONE AND/OR MICROPHONE INSTALLATION ................................................................. 49

6.8 REMOVING THE WATERPROOF CONNECTOR (WPC) ................................................................ 49

6.9 INSTALLING THE WATERPROOF CONNECTOR (WPC) .............................................................. 50

6.10 REMOVING THE BINDING POSTS .................................................................................................. 50

6.11 INSTALLING THE BINDING POSTS ................................................................................................ 50

6.12 WATERPROOF CONNECTOR (WPC) ASSEMBLY REBUILD ....................................................... 51

6.13 WATERPROOF CONNECTOR (WPC) PIN DIAGRAMS ................................................................. 52

6.14 POST DIVE MAINTENANCE ............................................................................................................. 52

EXPLODED VIEWS & PARTS LISTS ......................................................................................................... 54

Document # 001026001

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.

Morgan started design-

ing and making diving

equipment shortly after be-

coming a breath-hold diver

while working as a beach life-

guard in the late 1940s. There

was very little equipment avail-

able in those early days so it was

necessary to make much of his own

gear.

During the early 1950's Bev originated

the Los Angeles (California) Underwater

Instructor Program for teaching scuba

divers and instructors. A short time later

he started Dive ‘n Surf, one of the first

diving equipment suppliers to integrate

scuba diving instruction into the same op-

eration as sales and service of equipment.

Bev, along with his partners Bill and Bob

Meistrell, designed and manufactured div-

ing equipment whose basis remain as stan-

dards in the diving industry today.

In 1957 Morgan sold Dive ‘N Surf to

his partners and spent the next two years

cruising the South Pacific aboard a 60 ft.

ketch. After returning from the South Pa-

cific, Morgan began diving commercially

as well as designing and making diving

equipment for the commercial market.

The Kirby Morgan Corporation was

formed to manufacture commercial diving

helmets. The copper and brass “heavy

gear” or “Standard Dress” helmets were

the first helmets manufactured by the

company. Over the years Kirby Morgan

designed, manufactured and sold more

than thirty five diving helmets and thirty

four diving masks for commercial and mili-

tary divers. Many members of the DSI staff

participate as members of the Kirby Mor-

gan design team. It would not be possible

for us to supply the commercial, military,

scientific, and public service divers with

our Kirby Morgan Diving Equipment

without the team of people that make up

Diving Systems International, Inc. (DSI).

Bev Morgan, Chairman of the board,

Diving Systems International

A BRIEF HISTORY

EXO Full Face Mask Manual

Document # 001026001

To: Our Customers

We feel it is important for the reader to understand that we consider ourselves only a

part of the process along the path in diving equipment design. We welcome all input from

our customers. Many diving equipment engineers, diving medical specialists, diving or-

ganization administrators and their supporting personnel, along with thousands of divers

have contributed to the current state of the art of diving. Each piece of gear we manufac-

ture has in it some of the thinking of those who have gone before us. To all those people

who give something of themselves and to the men and women who work underwater, we

express a heartfelt thank you.

Providing the best diving equipment and service possible has always been and will

always be the policy of Diving Systems International Inc./Kirby Morgan.

Steve Kushner

Preesident, Diving Systems

Ce manuel convient aux modèles suivants

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