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KIRBY MORGAN SUPERLITE-17A/B

DIVING HELMET
OPERATIONS AND MAINTENANCE
MANUAL

DSI Part #100-001

Diving Systems International


425 Garden Street
Santa Barbara, CA 93101 USA
Tel. (805) 965-8538
FAX (805) 966-5761

DANGER: Diving with compressed breathing gas is a hazardous activity.


Even if you do everything right there is always the danger that you may be killed
or injured. No piece of diving equipment can prevent the possibility that you may
be killed or injured any time you enter the water.

Manual prepared by Marine Marketing and Consulting.

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.
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This page not used at this time.


SUPERLITE-17

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.

Change Number Date Description of Change Page Number

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SUPERLITE-17

MAINTENANCE LOG
SUPERLITE-17
Helmet Serial Number:

Repair Date Work Performed Performed By Checked By

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Contents SUPERLITE-17

CHAPTER 1.0 GENERAL INFORMATION .......................................................................... 1


1.1 INTRODUCTION .......................................................................................................... 1
1.2 THE KIRBY MORGAN DIVING HELMETS .................................................................. 2
1.3 DESIGN FEATURES OF THE SUPERLITE-17A/B ..................................................... 3
1.4 SPECIFICATIONS: SUPERLITE-17A/B ...................................................................... 4
1.5 GENERAL DESCRIPTION........................................................................................... 5
1.5.1 Helmet Shell ............................................................................................................ 5
1.5.2 Gas Flow Systems .................................................................................................. 5
1.5.3 Emergency Gas Supply System ............................................................................. 6
1.5.4 Helmet Attachment to the Diver .............................................................................. 7
1.5.5 Sealing Arrangement ............................................................................................... 7
1.5.6 Reducing Carbon Dioxide ....................................................................................... 7
1.5.7 Communications ..................................................................................................... 7
1.5.8 Equalizing the Sinuses and Inner Ear ..................................................................... 8
1.5.9 Face Port or Viewing Lens ...................................................................................... 8
1.5.10 Latch Catch Assembly, Pull Pin ............................................................................... 8

Chapter 2.0 OPERATING INSTRUCTIONS ........................................................................ 9


2.1 INTRODUCTION .......................................................................................................... 9
2.2 DESIGN PURPOSE ..................................................................................................... 9
2.3 FIRST USE OF SUPERLITE-17A/B DIVING HELMET ............................................. 10
2.3.1 Head Cushion ....................................................................................................... 11
2.3.2 Trimming the Neck dam ........................................................................................ 11
2.4 PRE DRESS-IN PROCEDURE .................................................................................. 12
2.4.1 Pre-Dive Visual Inspection .................................................................................... 12
2.5 PREPARING THE HELMET FOR DIVING ................................................................. 13
2.5.1 Clean Face Port .................................................................................................... 13
2.5.2 Check Moving Parts .............................................................................................. 13
2.5.3 Check Communications ........................................................................................ 14
2.5.4 One Way Valve Check .......................................................................................... 14
2.6 EMERGENCY GAS SYSTEM .................................................................................... 14
2.7 SETTING UP TO DIVE .............................................................................................. 16
2.7.1 Flushing Out the Umbilical .................................................................................... 16
2.7.2 Connecting the Helmet to the Diver’s Umbilical .................................................... 16
2.7.3 Opening the Breathing Gas Supply to the Helmet ................................................ 17
2.7.4 Fogging Prevention ............................................................................................... 18
2.7.5 Donning the SuperLite-17 ..................................................................................... 18
2.7.6 Testing the Breathing System ............................................................................... 22
2.7.7 Sealing Integrity Check ......................................................................................... 22

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2.8 DIVING PROCEDURES ............................................................................................ 23


2.8.1 Standing By to Dive ............................................................................................... 23
2.8.2 Attaching the Umbilical to the Harness ................................................................. 23
2.8.3 Diver Dons Helmet ................................................................................................ 23
2.8.4 Diver Check Gas Flow Systems ............................................................................ 23
2.8.5 Communications Check ........................................................................................ 23
2.8.6 Diver Ready .......................................................................................................... 23
2.8.7 Water Entry and Descent ...................................................................................... 24
2.9 EMERGENCY PROCEDURES .................................................................................. 24
2.9.1 Flooding ................................................................................................................ 24
2.9.2 Inhalation Resistance ............................................................................................ 24
2.9.3 Gas Flow Stops ..................................................................................................... 24
2.9.4 Demand Regulator Free Flow ............................................................................... 25
2.10 POST DIVE PROCEDURES .................................................................................... 25
2.10.1 Removing the Equipment .................................................................................... 25
2.10.2 Removing the SuperLite-17 ................................................................................ 25
2.10.3 Storage of the Helmet Between Dives ................................................................ 26

CHAPTER 3.0 TROUBLESHOOTING .............................................................................. 27


3.1 GENERAL .................................................................................................................. 27
3.2 COMMUNICATIONS MALFUNCTION ....................................................................... 27
3.3 ONE WAY VALVE MALFUNCTION ........................................................................... 28
3.4 SIDE BLOCK MALFUNCTION ................................................................................... 28
3.5 DEMAND REGULATOR MALFUNCTION.................................................................. 29
3.6 WATER LEAKAGE INTO HELMET............................................................................ 30
3.7 EMERGENCY VALVE MALFUNCTION ..................................................................... 30

CHAPTER 4.0 INSPECTION MAITENANCE TIMETABLE ............................................... 31


4.1 DAILY MAINTENANCE .............................................................................................. 31
4.2 MONTHLY MAINTENANCE ....................................................................................... 31
4.3 EVERY SIX MONTHS OR 200 OPERATING HOURS .............................................. 31
4.4 YEARLY OR 400 OPERTING HOURS ...................................................................... 31

CHAPTER 5.0 GENERAL PREVENTATIVE MAINTENANCE ........................................ 33


5.1 INTRODUCTION ........................................................................................................ 33
5.2 REQUIRED TOOLS, CLEANING AGENTS, LUBRICATION ..................................... 33
5.3 GENERAL .................................................................................................................. 34
5.4 DAILY MAINTENANCE .............................................................................................. 35
5.5 MONTHLY MAINTENANCE ....................................................................................... 37

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5.5.1 Yoke/Neck clamp Assembly .................................................................................. 37
5.5.2 Helmet O-ring ........................................................................................................ 37
5.5.3 Head Cushion ....................................................................................................... 37
5.5.4 Communications Inspection .................................................................................. 38
5.5.5 Lubricate Nose Block O-Rings .............................................................................. 38

CHAPTER 6 BREATHING SYSTEM MAINTENANCE AND REPAIRS ............................. 39


6.1 INTRODUCTION ........................................................................................................ 39
6.2 ONE WAY VALVE ...................................................................................................... 39
6.2.1 Disassembly of the One Way Valve ...................................................................... 39
6.2.2 Reassembly of the One Way Valve ....................................................................... 40
6.3 SIDE BLOCK ASSEMBLY .......................................................................................... 41
6.3.1 General ................................................................................................................. 41
6.3.2 Side block Assembly Removal .............................................................................. 41
6.3.2.1 Removal of Bent Tube Assembly ..................................................................... 41
6.3.2.2 Disconnecting the Hose Assembly ................................................................... 42
6.3.3 Separating the Side block Assembly from the Helmet Shell ................................. 42
6.3.4 Side block Assembly Replacement ....................................................................... 44
6.4 DEFOGGER VALVE .................................................................................................. 45
6.4.1 Disassembly of the Defogger Valve ...................................................................... 45
6.4.2 Cleaning and Lubricating ...................................................................................... 46
6.4.3 Reassembly of the Defogger Valve ....................................................................... 47
6.5 EMERGENCY VALVE ASSEMBLY ............................................................................ 48
6.5.1 Disassembly of the Emergency Valve Assembly .................................................. 48
6.5.2 Cleaning and Lubricating ...................................................................................... 49
6.5.3 Reassembly of Emergency Valve ......................................................................... 49
6.6 BENT TUBE ASSEMBLY ........................................................................................... 51
6.6.1 General ................................................................................................................. 51
6.6.2 Removal of the Bent Tube Assembly ................................................................... 51
6.6.3 Inspection of Bent Tube Assembly ....................................................................... 52
6.6.4 Replacement of Bent Tube Assembly ................................................................... 52
6.7 HOSE ASSEMBLY ..................................................................................................... 53
6.7.1 Hose Assembly Removal ...................................................................................... 53
6.7.2 Hose Assembly Inspection .................................................................................... 53
6.7.3 O-Ring Replacement ............................................................................................. 53
6.7.4 Hose Assembly Replacement ............................................................................... 53
6.8 DEMAND REGULATOR............................................................................................. 54
6.8.1 Demand Regulator Test for Correct Adjustment, Fully Assembled ....................... 54
6.8.2 Inspection of Regulator Body Interior .................................................................... 55
6.8.3 Adjustment System Lubrication ............................................................................. 56

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6.8.4 Reassembly of Adjustment System ....................................................................... 57
6.8.5 Demand Regulator Assembly Removal ................................................................ 58
6.8.6 Disassembly of the Demand Regulator ................................................................ 59
6.8.7 Inspection of Demand Regulator Parts ................................................................. 60
6.8.8 Cleaning and Inspection of Demand Regulator Parts ........................................... 60
6.8.9 Reassembly of the Demand Regulator ................................................................. 60
6.8.10 Tuning the Regulator ............................................................................................. 62
Important Notes on Regulator Adjustment:................................................................ 63
6.8.11 Regulator Steady Flows When Pressured Up, Special Tools Used ...................... 64
6.8.12 Regulator Steady Flows When Pressured Up, No Special Tools Available ......... 65
6.8.13 Regulator has Low or No Flow When Pressurized .............................................. 66
6.8.14 Unexplained Demand Regulator Steady Flow When Underwater ....................... 67
6.9 ORAL/NASAL............................................................................................................. 68
6.9.1 Oral/Nasal Removal .............................................................................................. 68
6.9.2 Inspection of Oral/Nasal ........................................................................................ 68
6.9.3 Oral/Nasal Replacement ....................................................................................... 69
6.10 WHISKER EXHAUST .............................................................................................. 69
6.10.1 Whisker Removal ................................................................................................ 69
6.10.2 Whisker Replacement ......................................................................................... 70
6.11 MAIN EXHAUST ASSEMBLY ................................................................................... 70
6.11.1 Main exhaust Valve Removal .............................................................................. 70
6.11.2 Main exhaust Valve Replacement ....................................................................... 71
6.11.3 main exhaust Body Removal ............................................................................... 71
6.11.4 Main exhaust Body Replacement ........................................................................ 71

CHAPTER 7.0 CORRECTIVE MAINTENANCE ................................................................. 73


7.1 GENERAL .................................................................................................................. 73
7.2 HELMET SHELL ........................................................................................................ 73
7.3 NOSE BLOCK ASSEMBLY ........................................................................................ 74
7.3.1 Nose BLock Assembly Removal ........................................................................... 74
7.3.2 Nose BLock Device Replacement ......................................................................... 74
7.4 HANDLE & WEIGHTS ............................................................................................... 75
7.4.1 Handle Removal .................................................................................................... 75
7.4.2 Handle Replacement ............................................................................................. 75
7.4.3 Weight removal ..................................................................................................... 76
7.4.4 Weight Replacement ............................................................................................. 77
7.5 ALIGNMENT SLEEVE ............................................................................................... 77
7.5.1 Sleeve Removal .................................................................................................... 77
7.5.2 Sleeve Replacment ............................................................................................... 77
7.6 PORT RETAINER ...................................................................................................... 78

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7.7 FACE PORT ............................................................................................................... 78
7.7.1 General ................................................................................................................. 78
7.7.2 Face Port and Nose Block Device Removal ........................................................ 78
7.7.3 Face Port and Nose Block Replacement .............................................................. 79
7.7.4 Special Note Regarding Ports ............................................................................... 81
7.8 COMMUNICATIONS .................................................................................................. 82
7.8.1 General ................................................................................................................. 82
7.8.2 Earphone Inspection ............................................................................................. 82
7.8.3 Microphone Removal & Replacement ................................................................... 82
7.8.4 Earphone Removal & Replacement ...................................................................... 83
7.8.5 Waterproof Connector ........................................................................................... 84
7.8.5.1 Connector Removal ........................................................................................ 84
7.8.5.2 Connector replacement ................................................................................... 85
7.8.6 Communications Posts ......................................................................................... 85
7.8.6.1 Communications Post Removal ...................................................................... 85
7.8.6.2 Communications Post Replacement ............................................................... 85
7.9 NECK CLAMP/YOKE ASSEMBLY ............................................................................. 86
7.9.1 Yoke ...................................................................................................................... 86
7.9.1.1 Yoke removal and Disassembly ...................................................................... 86
7.9.1.2 Yoke Replacement and reassembly ................................................................ 86
7.9.2 Latch Catch Assembly ........................................................................................... 87
7.9.2.1 Latch Catch Mechanism Disassembly ............................................................ 87
7.9.2.2 Latch Catch Mechanism Resassembly ........................................................... 88
7.9.3 Neck Clamp Assembly .......................................................................................... 88
7.9.3.1 Neck Clamp Assembly Adjustment ................................................................. 88
7.9.4 Neck Dam ............................................................................................................. 89
7.9.4.1 Neck Dam Removal ........................................................................................ 89
7.9.4.2 Neck Dam Replacement ................................................................................. 89
7.10 O-RING SEAL REPLACEMENT .............................................................................. 91
7.11 HEAD CUSHIOIN FOAM REPLACEMENT ............................................................. 91

Chapter 8.0 ACCESSORIES ..............................................................................................93


8.1 INTRODUCTION ........................................................................................................ 93
8.2 HOT WATER SHROUD INSTALLATION PROCEDURES ......................................... 93
8.3 LOW PRESSURE INFLATOR HOSE INSTALLATION ON THE B SIDEBLOCK ....... 96
8.4 WELD LENS ASSEMBLY .......................................................................................... 97
8.6 USE OF QUICK DISCONNECT ................................................................................. 98
8.7 DOUBLE EXHAUST INSTALLATION ........................................................................ 98

APPENDIX 1: TORQUE SPECIFICATIONS.. ...................................................................103


CONVERSION TABLES ...................................................................................................104
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SUPERLITE-17

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.

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

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

WARNING: Quest è un avviso importante. Tradurlo.

WARNING: Ceci est important. Veuillez traduire.

WARNING: Diese Mitteilung ist wichtig. Bitte übersetzen lassen.

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.

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SUPERLITE-17
IMPORTANT SAFETY INFORMATION
This SuperLite 17 diving helmet is intended for use by trained divers who have successfully
completed a recognized training course in surface supplied diving.

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.

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


cally contaminated is extremely hazardous. Although the SuperLite 17 diving helmet
may be adapted for use in some contaminated environments, special training, equip-
ment, 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 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.

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.

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.

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SUPERLITE-17

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.

DANGER: The standard SuperLite 17 diving helmet is not equipped or lubricated


for oxygen service. Using this helmet 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.

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SUPERLITE-17

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.

This warranty becomes null and void if:

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.

3) Unauthorized modifications have been made to the product.

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.

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Helmet shell
Handle

Free flow valve knob


Sideblock
Port retainer

Rear weight Regulator adjustment


knob

Emergency valve

Non-return valve

Regulator
Neck dam

Neck clamp

Waterproof connector

Fig. 1.1 The SuperLite-17B helmet with optional waterproof connector.


SUPERLITE-17
STOP!
BEFORE GOING FURTHER-

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.

Morgan started designing and making div-


ing equipment shortly after becoming a
breath-hold diver while working as a beach
lifeguard in the late 1940s. There was very
little equipment available in those early
days so it was necessary to make much of
his own gear.

During the early 1950s he originated the


Los Angeles County (California) Underwa-
ter Instructor Program for teaching scuba
divers and instructors. A short time later,
Bev started Dive ‘n Surf, one of the first Fig. 1.2 Bev Morgan
diving equipment suppliers that integrated Chairman of the Board
scuba diving instruction into the same op- Diving Systems International, Inc.
eration as sales and service of equipment.
He, along with his partners, Bill and Bob
Meistrell, designed and manufactured div- After returning from the South Pacific,
ing equipment that remain as standards in Morgan started commercial diving as well
the diving industry today. as designing and making diving equipment
for the commercial market.
In 1957 Morgan sold Dive ‘N Surf to his
partners and spent the next two years cruis- The Kirby Morgan Corporation was started
ing the South Pacific aboard a 60 ft. ketch. to manufacture commercial diving helmets.

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SUPERLITE-17
The copper and brass “heavy gear” or We have a strong interest in providing the
“Standard Dress” helmets were the first best diving equipment and service possible.
helmets manufactured by the company. This thinking has been the policy of Div-
Over the years Kirby Morgan designed, ing Systems International Inc./Kirby Mor-
manufactured and sold many different hel- gan and we will continue to take this ap-
mets and masks for commercial divers. proach to our work.
When business was slow there was always
an offshore job to fill in. 1.2 THE KIRBY MORGAN DIVING
HELMETS
Staying active in commercial diving has
helped us in the design improvements All Kirby Morgan diving helmets are manufac-
needed in our products. This may be the tured by Diving Systems International, Inc. (DSI).
primary reason for the acceptance of our Each step of the manufacturing process is care-
designs/products by professional divers. fully controlled to assure the customer of a high
quality, durable helmet that will function prop-
Morgan has designed more than thirty five erly.
diving helmets and thirty four diving
masks. Many other members of the DSI There are three different Kirby Morgan diving
staff participated as part of the Kirby Mor- helmets in production at this time. They are the
gan design team. It would not be possible SuperLite-17A/B, the SuperLite-17C, and the Su-
for us to supply the commercial, military, perLite-27. The SuperLite-17A/B was first devel-
scientific, and public service divers with oped in 1975 and quickly set a new standard for
our Kirby Morgan Diving Equipment with- diving helmet design. This design has been suc-
out the team of people that make up Div- cessfully used around the world by many large
ing Systems International, Inc. (DSI). and small commercial diving companies, military
organizations, scientific divers, and public safety
We feel it is important for the reader to divers.
understand that we consider ourselves only
a part of the process along the path in div- The SuperLite-27 was developed in 1992. It fea-
ing equipment design. We welcome all in- tures a unique locking collar design and a low
put from our customers. The thinking of volume. It shares many common breathing sys-
many good diving equipment engineers, tem parts with both the SuperLite-17A/B and the
diving medical specialists, diving organi- SuperLite-17C. This breathing system has been
zation administrators and their supporting man-tested to 1600 FSW by the University of
personnel, along with the divers themselves Pennsylvania and approved by the U.S. Navy
have contributed to the current state of the Experimental Diving Unit for use to 850 FSW.
art of diving.
Other features that are common to all three hel-
Each piece of gear we manufacture has in mets include:
it some of the thinking of those who have
gone before us. To all those people who • the face port and retainer ring
give something of themselves to the men • communications components
and women who work underwater we ex- • the oral/nasal mask
press a thank you. • the nose block device
• the air train

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The breathing system components on these three helmets are also compatible with our Kirby Morgan
Band Mask, models 18A/B and 28B. This helps reduce the inventory of spare parts that must be
carried by commercial diving companies.

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.

1.3 DESIGN FEATURES OF THE SUPERLITE-17A/B


The key features of the SuperLite-17A/B include:

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.

5) The communications system (74) is a modular, quick change design.

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

1.4 OPERATIONAL SPECIFICATIONS: SUPERLITE-17A/B

Operational Specifications and Limitations:


- Maximum depth on air - 220 fsw (67 msw) with The umbilical assembly should be composed of
the standard exhaust whisker assembly. good quality diving hose that meets industry stan-
dards. Generally, gas hose will be married to the
- Maximum depth on air - 100 fsw (30 msw) when
communications wire, pneumofathometer hose,
equipped with the double exhaust whisker
and strength member in a manner that will allow
assembly*.
the strength member to receive all the strain. There
Work rate - moderately heavy - 62.5 lpm rmv. are also good quality umbilicals available that are
assembled at the factory using a twisted method
-Umbilical minimum I.D. 3/8” (9.5 mm) of one which does not require marrying. Regardless of
continuous length (no splice), total length not to the system used, the umbilical is the divers life
exceed 600 feet (182m). line and should always be of excellent quality and
maintained carefully.
-Required over-bottom supply pressure,
0-l00 fsw (0-30 msw), 115-135 psig (8-9.3 bar). Weight 29 pounds

100-150 fsw (30-50 msw),135-225 psig (9.3-15.5 bar). Construction


Helmet shell Fiberglass, polyester resin and carbon fiber
100-220 fsw (30-67 msw),175-225 psig (12.0-15.5 bar). Stainless steel, chromed brass, polished brass, powder
Hardware
coated anodized aluminum
Control Knobs ABS plastic
-Gas supply system capable of supplying 4.5 Lens/face port Plycarbonate
acfm (127.4 BL/min) to the side block assembly Neck dam Neoprene only
O-rings Buna-N
at depth.
Head Cushion
Bag Nylon
-Temperature limitations: Use at water tempera- Foam #4 Ester

tures below 36o F (2oC) requires use of hot water Communications


Earphones Mylar cone speakers, 8 ohm, chrome casing
shroud and hot water. Microphone 8 ohm
Adjustment of helmet fit Through use of head cushion chin strap
External Weights Three
* This assembly has not been tested for CE com- Mount brackets for
None, handle can be drilled for mounting
pliance. Only equipment certified and tested ac- accessories
Recommended lubricants Dow Corning DC111, DC 055
cording to EN 250/E DIN 58 642 may be used Operating Pressure 115-225 p.s.i. over ambient

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.

PAGE 4 Docu# 010502002


SUPERLITE-17
1.5 GENERAL DESCRIPTION
1.5.1 HELMET SHELL
The helmet shell (92) is fabricated of noncorro-
sive, rigid fibergass which will not carry an elec-
trical charge. This shell is the central structure
for mounting all the components that make up
the complete helmet. It is designed to allow easy
replacement of parts when necessary. Any repair
to the helmet shell must be done at an approved
DSI repair center.

1.5.2 GAS FLOW SYSTEMS


The main gas supply flow from the umbilical en-
ters the system at the adapr (67) antd flows
through the automatic oe way valve (68) to the
interior of the side block assembly (43a/b). The
one way valve or “non-return” is a very impor-

Docu# 010502002 PAGE 5


SUPERLITE-17
dump) (149-152) valve, or into the oral/nasal (83) WARNING: Users of the Kirby Mor-
by means of the valve (84,85), then into the regu- gan diving helmet side block low pressure
lator (138a/b) and out through the regulator ex- inflator port are cautioned to use only high
haust. The diver can breathe from this flow of quality hoses and fittings for low pressure
gas if the demand regulator malfunctions. inflators, as provided by the manufactur-
ers of these systems. These hoses must
Returning to the side block assembly: the other have an in-line restrictor to reduce gas
passage for gas is to the demand regulator (138a/ flow in the event of hose failure. Any hose
b). It goes to a bent tube assembly (47b) or a or fitting failure in this arrangement will
hose assembly (47a) that connects to the inlet subject the diver to a decreased air sup-
nipple of the demand regulator (130a or 132b). ply.
The flow of gas in the demand regulator assem-
bly is controlled by an automatic valve that sup-
plies gas to the diver on inhalation “demand” only, 1.5.3 EMERGENCY GAS SUPPLY SYSTEM
and shuts off during the exhalation cycle. We strongly recommend that the working diver
carry an independent supply of compressed gas
The SuperFlow demand regulator senses the start (or air) fitted with a first stage regulator and hose
of the divers inhalation and opens the flow valve, that is connected to the inlet of the emergency
matching the diver’s need. The regulator contin- valve.
ues to match the diver’s inhalation as the rate in-
creases, peaks, then ebbs and stops. When the WARNING: Be sure the emergency
diver exhales, the supply gas stays off as the ex- air/gas first stage regulator is fitted with
halation gas flows through the regulator body, out a relief valve for over-pressurization of the
the regulator exhaust valve, through the whisker supply hose. A leaky first stage can over-
(139), and out into the water. The whisker de- pressure the hose, bursting it. This would
flects the exhaust bubbles away from the face port cause a loss of the entire bailout supply
(142) to keep the diver’s view clear. and possible physical injury to the diver
as the hose whips about. Do not use a
The adjustment knob (120) allows the diver to high pressure hose, as the system on the
control the regulator for a wide range of incom- helmet is not designed for high pressure.
ing gas pressures. Normally, this would be from
115 P.S.I. to 225 P.S.I. over ambient (diver) pres-
sure. It is important to have this control at the
diver for the least breathing resistance.

The side block on the “B” model helmet (43b) is


drilled and tapped to accept low pressure inflator
hoses. This allows the diver the capability to in-
flate variable volume dry suits or buoyancy com-
pensators. It is tapped with a 3/8"-24 thread ori-
fice, standard for American first stage scuba Fig. 1.6 Shown are the three versions of the over
regulator’s low pressure auxiliary fittings. The pressure relief valve, current model on the far
port is shipped plugged (48) at delivery. This in- right. Every bail-out regulator must be fitted with
flation capability does not interfere in any way a relief valve to help prevent over-pressurizing
with the breathing characteristics of the regula- the supply hose.
tor.

PAGE 6 Docu# 010502002


SUPERLITE-17
1.5.4 HELMET ATTACHMENT TO THE DIVER If you must trim the neck dam, be careful not to
trim off too much material. The neck dam must
On the SuperLite-17, the helmet shell has an o- fit snugly. While it may be a slight bit uncom-
ring seal (80) around the base of the fiberglass fortable out of the water, it should be unnotice-
rim. The helmet is held in place on the diver’s able underwater.
head by the yoke/neck clamp (7, 22, 23-31) which
mounts on the diver’s neck and seals to the bot- CAUTION: Pulling the neck dam
tom rim of the helmet. over the diver’s head can be difficult.
Stretching (expanding) the seal and plac-
The head cushion (1) is made from layers of open ing part way over the head can help re-
cell foam inserted in a head shaped nylon bag. duce the force needed to install the seal.
The fit of the head cushion can be adjusted by Proper training is necessary to install the
adding or subtracting foam layers from the bag. neck seal over the diver’s head and onto
The head cushion must be adjusted correctly for his neck. Although the possibility is very
the helmet to fit properly. remote, injury may result if this procedure
is not done properly. If a diver does not
1.5.5 SEALING ARRANGEMENT know how to don the neck seal he must
seek proper instruction before proceed-
The neck dam (140), is available in two sizes, a ing.
standard and an extra-large size, and is fabricated
in a cone shape. The neck dams on all SuperLite- 1.5.6 REDUCING CARBON DIOXIDE
17A/Bs are made of foam neoprene.
It is important to reduce the volume of air/gas
The neck dam seals against the diver’s neck. The space that the diver is breathing through. Carbon
fit of the neoprene neck dam may be made larger dioxide (CO2) can build up if proper flushing does
by stretching the neck dam over a scuba cylinder not occur. A rubber oral/nasal mask (83) is lo-
overnight. This is the preferred method of enlarg- cated inside the helmet to fit over the diver’s nose
ing the neck dam and should be attempted first if and mouth. The oral/nasal attaches to the regula-
the neck dam is too tight. In some cases, the neck tor mount nut (82). This separates the breathing
dam may need to be trimmed. gas flow from the larger gas space on the interior
of the helmet, and this in turn reduces carbon di-
oxide buildup.

WARNING: Always be sure the oral/


nasal valve is properly mounted in the
oral/nasal mask. If the valve is mounted
improperly or is absent this can lead to a
higher CO 2 level inside the helmet. A
higher CO2 level can cause dizziness, nau-
sea, headaches, shortness of breath, or
blackout.

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.

Docu# 010502002 PAGE 7


SUPERLITE-17
In the SuperLite-17A/B, both earphones (71, 72) 1.5.10 LATCH CATCH ASSEMBLY, PULL
and microphone (73) are wired in parallel. The PIN
communications are connected to either a water-
proof connector (164), or binding posts (154) for The latch catch assembly (22) includes the pull
bare wire connection. pin and safety pin (18). The purpose of this as-
sembly is to ensure that the neck clamp assembly
Electrical signals are sent to, and received from, remains securely fastened around the base of the
the surface through the umbilical wires. An am- helmet so that the helmet remains on the diver.
plifier boosts the signals to the desired volume This arrangement functions in a similar manner
for the surface and the diver. to the old “dummy pin” on a heavy gear helmet.
1.5.8 EQUALIZING THE SINUSES AND INNER
EAR WARNING: When purchasing spare
A nose block device (86) allows the diver to block parts, always insist on Kirby Morgan
his nose to provide an overpressure in his sinus Genuine parts. Although other parts may
and inner ear for equalization. The blocking pad look the same, they may not be manufac-
on the inside of the oral/nasal mask is attached to tured to the same standards of quality.
a shaft which passes through a packing gland to Look for this logo to be assured that you
the outside of the helmet. A knob attached to the are purchasing the correct parts for your
end of the shaft can be pushed in to slide the pad helmet. Improperly manufactured parts
under the diver’s nose. can cause accidents.

When not needed, the knob is pulled out so the


pad does not rub under the diver’s nose. The pad
may also be turned upside down (to provide more
KIRBY MORGAN
TM

clearance under the diver’s nose) by rotating the


shaft.

1.5.9 FACE PORT OR VIEWING LENS


The face port or viewing lens (142) is extremely
strong plastic.

The port retainer is easily removable for replace-


ment of the lens. An o-ring (143), located under
the lens, seals the lens to the fiberglass helmet
shell.

DANGER: The port retainer screws


must be tightened to proper torque speci-
fications per the instructions in this
manual. See Appendix 1 for proper torque
specifications. Do not over tighten.

PAGE 8 Docu# 010502002


SUPERLITE-17

CHAPTER 2.0
OPERATING INSTRUCTIONS

WARNING: This manual is our effort to explain the operation, maintenance


and use of the SuperLite-17A/B diving helmets. We do not herein make any effort to
teach the principles of diving. It is our assumption the reader is a qualified diver.
All divers must train in the use of any model of commercial diving helmet, under
controlled conditions, if they have not previously used or trained in that particular
helmet prior to use on the job.

2.1 INTRODUCTION 2.2 DESIGN PURPOSE


This section provides the manufacturer’s advice All Kirby Morgan diving helmets are designed
on how to use the SuperLite-17A/B diving hel- for use with an umbilical.
mets. The use of these diving helmets will vary
WARNING: Only under very con-
with the type of work and environmental condi-
trolled conditions, i.e., non-moving wa-
tions. The basic procedures of donning and re-
ter (such as swimming pools or calm
moving these helmets will be similar for every
lakes), should the SuperLite-17 helmet
job.
be used with a self contained gas sup-
ply. There is no provision for surface
A proper training program in a calm, clear body
swimming once the scuba air supply is
of water must be undertaken, if possible. If the
depleted. Adequate support personnel
diver has not used a particular Kirby Morgan hel-
for the conditions must be available to
met before, he must not dive with that helmet
assist the diver to assure his safety.
without proper training. However, divers that are
familiar and trained in the use of previous Kirby The umbilical is usually composed of, at a mini-
Morgan masks; i.e., KMB 8, 9, 10, 18, 28, the mum, a gas or air supply hose and communica-
Navy Mk. 1 mask, Navy MK. 21 helmet, the tion wire, assembled with tape (and in some um-
SuperLite-27, the SuperLite-17C or the Navy Mk. bilicals wound similar to strands in a rope) to form
22 mask will find that all Kirby Morgan diving a single unit. Some umbilicals also have included
helmets have the breathing system controls lo- a hose for hot water, a pneumofathometer hose,
cated in the same position and the operation of and a strength member, such as a cable or strong
the SuperLite-17 will be similar. line. The umbilical is the diver’s lifeline to the
diving control station.
The diver must be tended at the surface at all times
by a trained, qualified diving tender, knowl- The diver must be tended at the surface at all times
edgable in surface supplied diving procedures. by a trained, qualified diving tender. Never dive
Never dive without a qualified tender holding without a qualifed tender holding your diving
your diving hose. hose.

Docu# 010502002 PAGE 9


SUPERLITE-17
The diving control station can be at the surface,
in a diving bell, or out of a submerged habitat. WARNING: High pressure regula-
The diving control station is the center of the tors for surface supplied diving with
breathing gas supply, communications with the SuperLite-17A/B diving helmets must be
diver, and diving procedures. The station can be capable of supplying an over bottom
as simple as a tender with a set of “phones” (com- pressure of between 115 and 225 PSI.
munication amplifier), or as complex as a con- The use of standard SCUBA style regu-
trol van in a saturation system. lators stationed at the surface is unac-
ceptable as there is no provision for
Diving Systems International manufactures a adjusting the intermediate pressure
complete Dive Control Systems, the DCS-2A™ supplied to the diver. This can create a
with integrated communications and pneu- dangerous situation where the diver
mofathometer. This portable system can be oper- may not receive an adequate supply of
ated on either a high pressure air supply or on a air. Only regulators which allow a vari-
low pressure compressor. The Dive Control Sys- able setting for intermediate pressure
tems has a specially designed high pressure regu- should be used for umbilical diving.
lator that reduces high pressure air and provides The surface supplied diver’s helmet must provide
an adequate flow to support divers to a depth of life support breathing systems, communications
130 FSW.
components, viewing lens, and many other less
important, but vital systems. All Kirby Morgan
diving helmets provide these systems in a conve-
nient and comfortable way.

2.3 FIRST USE OF SUPERLITE-17A/B


DIVING HELMETS

When you first receive your SuperLite-17A/B


diving helmet, carefully unpack it and examine it
for any damage that may have occurred during
shipment. Use the inspection sheet provided to
ensure that no damage has occurred during ship-
ment. The purchaser must contact the freight car-
rier and/or the DSI dealer if the helmet has been
damaged in shipment.

Be sure to complete the enclosed warranty card


and return it to DSI immediately. No warranty
claims will be honored without a correctly com-
pleted warranty card on file at DSI.
CAUTION: DSI must have your
current address to assure that you re-
Fig. 2.1 The DCS-2A™ is just one type of ceive all safety notices and other im-
surface supplied diving console for air diving. portant information concerning the
helmet. Please notify DSI of any
change of address.

PAGE 10 Docu# 010502002


SUPERLITE-17
2.3.1 HEAD CUSHION
The fit of the helmet is primarily determined by
the layers of open cell foam that fill the head cush-
ion bag.

The diver’s head can be moved forward into the


oral/nasal mask by increasing the thickness of the
foam at the rear of the head cushion. The diver’s
head can be moved up or down in the helmet by
decreasing or increasing the foam pads at the top
of the head cushion. Usually, a diver with a small
head will require all the foam that comes with a
new hat. A diver with a larger head will need to
remove some foam in the center top and back of
the head cushion. The foam may be cut with scis-
sors to provide a better fit, or more foam can be
added to give a tighter fit.

On the SuperLite-17 there is a chin strap to fur-


ther help adjust the fit of the head cushion.

Fig. 2.3 Try stretching the neck dam first and


see if you can obtain a good fit this way before
trimming it.

WARNING: Never dive with a neck


dam that is too tight. A neck dam that is
too tight could cause the diver to pass
out due to pressure on the carotid ar-
tery in the neck.

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.

Docu# 010502002 PAGE 11


SUPERLITE-17
2.4 PRE DRESS-IN PROCEDURE
Before dressing in for a dive, inspection of the
helmet system must be made to be sure it is in
proper working order. This must be done well in
advance of the dive, so any problems can be fixed
without delaying the dive. The following steps
are part of the recommended daily maintenance.

2.4.1 PRE-DIVE VISUAL INSPECTION

Visually inspect the exterior and interior of the


helmet.
Fig. 2.4 If a proper fit cannot be obtained by
stretching the neck dam, it must be trimmed.
1) The demand regulator cover (123) should not
be dented.
If you still feel the neck dam is too tight, then
you can stretch it by sliding it over a scuba tank 2) The neck dam (2) must not be torn or punc-
and allowing it to sit overnight. If you still can- tured.
not get the proper fit by stretching the neck dam,
it must be trimmed further. Do not trim more than WARNING: There must be no
1/4 inch at a time. holes in the neck dam. If there are any
holes in the neck dam the helmet could
CAUTION: Avoid trimming neo- leak or flood. In addition, the demand
prene neck dams too much. Neoprene regulator will not operate properly.
neck dams will loosen over time as they Drowning could result.
are used and the cells of the foam neo-
prene break down. If you trim the neck 3) The o-ring (80) that goes around the base of
dam too much it will be too loose and the helmet (92) shell must be in place and un-
will leak. Trim the neck dam until it is damaged.
snug, then stretch it before using it.
DANGER: The o-ring on the base
As the neoprene neck dam ages, it will become of the helmet on the SuperLite-17 must
looser, due to a natural breakdown of the cells. be in place and in good condition. With-
This is particularly true if the helmet is locked in out a proper functioning o-ring the hel-
and out of a saturation or bell system. As the neck met will leak and possibly flood. Drown-
dam becomes worn it will need replacement to ing could result.
ensure that it seals properly.
4) Inspect the bent tube (45b) (or hose if so
equipped) that supplies breathing gas to the regu-
lator. There must be no dents or kinks in the as-
sembly.

5) Inspect the face port (142). It must be in good


condition.

6) Be sure the communications wires are hooked


up and there are no loose nuts (145).

PAGE 12 Docu# 010502002


SUPERLITE-17
7) Inspect the oral/nasal mask (83). Make sure it DANGER: All parts on SuperLite-
is on the regulator mount nut (82) properly. 17A/B diving helmets must be adjusted
to their proper torque specifications.
8) Inspect the yoke/neck clamp (7) and latch catch See Appendix 1 for a complete listing of
mechanism (22). They must engage and disen- torque specifications for each part. Fail-
gage properly. ure to adjust parts to the recommended
specifications could lead to helmet fail-
9) Make sure the head cushion (1) is properly fas- ure and accidents. This could be fatal.
tened inside the helmet.
2.5 PREPARING THE HELMET FOR DIVING
2.5.1 CLEAN FACE PORT

Remove any sand or dirt on the interior of the


face port. Use a mild solution of soap and water
to clean the port.
2.5.2 CHECK MOVING PARTS
Check all moving parts, such as the regulator ad-
justment knob (120), the defogger control knob
(34), emergency knob (55), and the nose block
device knob (108) to ensure smooth and proper
operation.

Fig. 2.5 Make sure the head cushion is properly


installed in the helmet.

10) Check the screws on the port retainer (104).


They must be adjusted to the proper torque set-
ting per the specifications in Appendix 1 of this
manual. Binder head screws are used in this ap-
plication for their self locking characteristics.
Overtightening may strip out the threaded inserts
in the helmet shell.

Fig. 2.6 Check the moving parts to ensure they


work properly.
Docu# 010502002 PAGE 13
SUPERLITE-17
2.5.3 CHECK COMMUNICATIONS the adapter or (if attached) into the unpressurized
Check the communications system for proper umbilical hose, the one way valve is faulty and
operation. Put the helmet on and talk to an assis- must be replaced. Flow into the unpressurized um-
tant on the amplifier. If you are testing the unit bilical hose can be heard. A repair kit is available
by yourself, with the helmet off, take the helmet for rebuilding these valves (DSI Part # 525-330).
near the amplifier and tap each earphone and the
WARNING: Never dive if the one
microphone, listening to the taps on the ampli-
way valve is not operating properly. If
fier/speaker. Talk into the amplifier/speaker feel-
the hose or breathing gas/air fitting
ing the vibration on each earphone and the mi-
breaks near the surface a serious injury
crophone with your fingertips.
could result to the diver’s lungs and/or
eyes. In extreme cases this could be fa-
tal.

2.6 EMERGENCY GAS SYSTEM


If the diver’s incoming main air/gas supply fails,
the diver must have another source of breathing
gas that will enable a safe return to the diving
station. A tank of compressed breathing gas is
usually worn by the diver. Exactly how the tank
is carried, and the capacity of the tank, depends
on the individual’s preference and the circum-
stances of the job.

Fig. 2.7 Be sure to test the one way valve.


2.5.4 ONE WAY VALVE CHECK
There are two ways to check the one way valve.
Check both ways if possible.

1) Leave the emergency valve knob (55) open.


Do not connect the supply hose. Try to suck air
out of the adapter (67). If any air comes out, the
one way valve must be replaced.

2) Prior to attaching (or pressuring up) the um-


bilical, close the emergency valve knob (55), at-
tach and pressure up the emergency hose. Shut
off the defogger control knob (34) and screw ad-
justment knob (120) on the regulator all the way
in. With the emergency hose pressurized, turn on Fig. 2.8 All surface supplied divers need a
the emergency valve knob. If gas escapes out harness.
PAGE 14 Docu# 010502002
SUPERLITE-17
Most commercial divers wear a harness (sepa-
rate from the weight belt) that is used for several
purposes. The harness is fitted with large metal
rings (usually brass or stainless steel). The um-
bilical is hooked into one of these rings to keep
any strain off the helmet. In addition, the rings
on the harness are used to hang tools and other
equipment. Usually, the harness is also designed
to provide a means of lifting an unconscious diver
from the water. This harness is the best method Fig. 2.9 Always use an over-pressure relief
of securing the emergency breathing gas to the valve on your bail-out regulator.
diver.

A small tank can be mounted horizontally on the


lower rear or front, while larger tanks are usually WARNING: Never connect the
mounted vertically in the center back, similar to high pressure hose directly to the emer-
a scuba diver’s tank. Some harness designs in- gency valve assembly , as this will trans-
corporate a cloth enclosure into which the tank mit the full pressure of the tank to the
fits. The entire tank, valve, and regulator are en- side block. The side block is not de-
closed in fabric. This helps to prevent snagging. signed for high pressure.

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-
Docu# 010502002 PAGE 15
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.

Connect the proper end of the umbilical to the


topside breathing gas supply. Be sure to hold the
open end of the umbilical so the hose doesn’t whip
about once the air is turned on. Remove the cap
from the open end of the umbilical and turn on
the topside air supply. Keep a firm grip on the
hose and do not point the open end of the hose at
Fig. 2.10 The diver should always wear a bail-
anyone. Turn the air supply off before attempting
out bottle.
to connect the umbilical to the helmet.

2.7.2 CONNECTING THE HELMET TO THE DIVER’S


UMBILICAL
When you connect the hose to the helmet, be sure
to use a wrench to hold the adapter (67), or inlet
fitting, and a second wrench to turn the fitting on
the hose. If this is not done, the adapter will turn
inside the one way valve (68). If this happens re-
peatedly the threads will wear and the valve will
need to be replaced. The connection between the
hose and the helmet must only be made up “snug”.
Excessive force will deform and ruin the adapter.
A second wrench must be used when the helmet
is disconnected as well, otherwise the adapter and/
or the one way valve assembly may become loose
and fail to make a seal.

DANGER: If the one way valve or


the adapter is loosened breathing gas
will leak out of the breathing system.
This could also result in a loss of all
pressure to the helmet, leaving the diver
with nothing to breathe.
Fig. 2.11 Always check the pressure in the bail-
out bottle before diving. If you are using waterproof connectors (158) for
your communications, take extra care in handling
these pieces. To connect the male and female
parts, align the large pin on the male connector
cated on the side block is turned on, supplying with the yellow mark on the female connector.
gas to the side block assembly and the demand Press the two connectors together until you hear
regulator assembly. a distinct “pop”. Do not twist the connectors.
PAGE 16 Docu# 010502002
SUPERLITE-17
nectors are disconnected. Do not twist the con-
nectors. Do not pull them apart while holding
onto the thinner part of the wire that is away from
the connectors.

Fig. 2.12 Connect the hose to the adapter.

Fig. 2.14 Connect the waterproof connectors.


2.7.3 OPENING THE BREATHING GAS SUPPLY TO
THE HELMET

Prior to turning on the air supply for the helmet,


check to see that the free flow valve knob (34) is
closed. If the regulator adjustment knob (120) is
screwed out all the way, in its storage position,
screw it in all the way. The umbilical air, or gas
supply is turned on pressurizing the side block
and regulator. Now unscrew the regulator adjust-
ment knob until a slight steady flow is present,
then turn it back in until it just stops.
Fig. 2.13 Use two wrenches to tighten the hose.
To properly check the breathing system on all
Tape the two connectors with a bit of electrical SuperLite-17A/B diving helmets you must com-
tape to prevent them from pulling apart. pletely don the helmet.
To separate the connectors remove the tape, grasp
them at the thickest part, place your thumbs
against each other, and push apart until the con-

Docu# 010502002 PAGE 17


SUPERLITE-17
2.7.5 DONNING THE SUPERLITE-17

If the yoke/neck clamp assembly is connected to


the helmet, it must be removed before you can
don the helmet. To release the neck clamp, you
must first remove the safety pin (18) that engages
the latch catch assembly (22). Squeeze the pin
between your thumb and forefinger until you can
open it and slide the straight pin out of the latch
catch assembly.

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).

To don the helmet, hold the yoke/neck clamp in


your hands in front of your body. Swing the neck
Fig. 2.15 Screw in the regulator adjustment
clamp assembly (7) up towards your chest. Lift
knob before you turn the air on to the helmet.
the entire unit over your head until the opening
2.7.4 FOGGING PREVENTION for the yoke (31) is positioned at the back of your
neck. Slide the yoke forward until it is centered
A thin film of anti-fogging solution must be ap- around your neck.
plied to the interior of the face port (142) prior to
the dive to help prevent fogging during the dive. Reach over your head and insert the four fingers
A mild liquid dish washing detergent, or other of each hand in the opening of the neck dam (2).
commercially available anti-fogging solutions, Keep your thumbs on the outside of the neck dam.
may be applied with a soft rag or paper towel to Spread the neck dam by pulling against the palms
the interior of the port. The diver should use what- of each hand. Pull the neck dam over your head.
ever solution he has found satisfactory in the past. Turn the neck dam so that the top edge is up and
However, do not use an aerosol spray on the out.
port lens. The propellants in some aerosol dis-
pensers cause damage to the port lens. WARNING: The neck dam must al-
ways be turned up and out. This is es-
DANGER: Never use any aerosol sential. With the neck dam turned down,
propelled sprays near the face port of
the helmet will vent air from the neck
the SuperLite-17. The Freon propellant
dam, causing the regulator to free flow.
used in these aerosols can invisibly
This will make the helmet very uncom-
damage the face port and cause it to
fortable and could lead to a rapid deple-
shatter upon impact from any strong
tion of the breathing supply when us-
blow. If the face port fails underwater the
ing bottled breathing gas. Always keep
helmet will flood and drowning may re-
the neck dam turned up.
sult.

PAGE 18 Docu# 010502002


SUPERLITE-17

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.

Place the helmet face down and locate the tab on


the end of the head cushion (1). Loosen the tab
completely. Grab the base of the helmet with both
hands while you hold the head cushion open. Lift
the helmet over your head and carefully lower it
onto your head, pushing your head into the rear
of the helmet.

Pull the helmet down and from side to side until


it is comfortable on your head. Position the neck
strap under your chin. Pull the strap down and
back towards your right until it is snug, but com-
fortable. Reach up inside the helmet and fasten
the strap under your chin by attaching it to the
Velcro® tab on the right side of the head cushion.
Take care to prevent the end of the strap from
becoming fastened between the helmet shell and
the neck dam.

Fig. 2.17 Don the neck dam by carefully pulling


it over your head.

Docu# 010502002 PAGE 19


SUPERLITE-17

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. 2.20 Grab the head cushion and spread it


while grasping the side of the helmet and
holding the chin strap.

CAUTION: Be sure to fasten the


chin strap on the head cushion. If the
chin strap is not fastened properly, the
helmet will float up on the diver’s head.
This will make the helmet very uncom- Fig. 2.22 Lift the helmet over your head.
fortable. Hold the handle on the neck clamp assembly with
your right hand, lift it up, and swing it to your
Tilt your head back and push the entire neck clamp right. This action will open the neck clamp fully.
assembly and yoke backwards on your neck. The Lift up on the clamp and push down on the hel-
front edge of the neck clamp (7) should be under met with your left hand until the clamp is seated
and past the front edge of the helmet. Keep your against the bottom of the helmet.
head tilted back, and lift the front of the helmet
up with one hand. With your free hand, reach back While maintaining pressure on both the helmet
behind your head until you can find the rear hinge and the clamp, swing the handle on the clamp to
tab (26) on the back of the yoke. Lift the rear hinge your left. Once the handle passes the “over-cen-
tab out away from the helmet and up until it can ter” position, and is almost all the way to the left,
slide over the alignment sleeve on the back of the remove your left hand from the top of the helmet
helmet. Slide the tab over the sleeve. and open the latch catch assembly by pulling out
PAGE 20 Docu# 010502002
SUPERLITE-17

Fig. 2.23 Tighten the chin strap. Fig. 2.26 The clamp will close easier once the
handle has passed over center.

Fig. 2.24 Place the rear hinge tab on the


alignment sleeve.

Fig. 2.27 Have your tender install the safety


pin.
on the pull pin knob until it stops. Push the handle
on the latch catch assembly against the helmet.
With the handle against the helmet, push down
gently until the handle bottoms out against the
latch catch assembly. Push the pin on the latch
catch assembly in until it stops. The helmet is now
locked into place and you can test the breathing
system properly.

If you are ready to dive, have your tender install


Fig. 2.25 Close the neck clamp. the safety pin before you enter the water.

Docu# 010502002 PAGE 21


SUPERLITE-17
2.7.6 TESTING THE BREATHING SYSTEM between his neck and the sealing neck dam and
pull the neck dam away from the neck to allow
Test the defogger system by turning on and off breathing. Turn the supply gas off at the dive con-
the defogger control knob (34). The regulator trol system and bleed the umbilical.
should be adjusted by turning the adjustment knob
(120) out until a slight steady flow starts, then With the yoke/neck dam on the diver’s head, the
back in until the flow just stops. Next, the de- helmet is installed and the neck clamp is closed.
mand regulator system is checked for proper func- When the diver attempts to inhale, a suction on
tion: breathe in and out. Inhalation and exhala- the neck dam is formed, indicating he is achiev-
tion effort should be nearly unnoticeable. Press ing a good seal. The diver must then turn the air
in on the purge button in the regulator cover (123). on immediately so that he can breathe. If the diver
This should produce a strong burst of breathing does not turn the air on he will not be able to
gas. breathe, unless the neck dam (2) is pulled away
from his neck.

DANGER: Do not perform this test


unless the diver is stationed immedi-
ately adjacent to the diver’s air manifold
and you are certain the air is on to the
manifold. If the diver is unable to flow
air to the helmet, either through the um-
bilical or the bailout, he may not be able
to remove it easily. To break the seal in
this situation, the diver must put his
hand between the neck dam and the
neck, and pull the neck dam away from
the neck. A tender must be standing by
to assist the diver in removing the hel-
met if needed.

To remove the SuperLite-17, you must first re-


move the safety pin. Squeeze the pin to disen-
gage it and pull it away from the latch catch body.

Reach up with your left hand and pull out on the


pull pin of the latch catch assembly with the fin-
gers on your left hand. At the same time, grab the
Fig. 2.28 The diver must satisfy himself that the handle on the neck clamp assembly with your
helmet is operating properly. right hand, lift it up and pull outwards away from
the helmet, until the handle is in front of your
2.7.7 SEALING INTEGRITY CHECK
face. This action will break the seal of the neck
If there is any doubt that the helmet is sealing dam around the base of the helmet and the neck
properly, perform the following test prior to div- dam will fall away from the bottom of the hel-
ing. met.

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.

Reach in and spread the neck dam, pulling against


the sides of the neck dam with the palms of both
hands. Lift the neck dam over your head. Slide
the yoke backwards away from your neck to re-
move it.

2.8 DIVING PROCEDURES


2.8.1 STANDING BY TO DIVE

The diver may wear the neck dam ring assembly


without discomfort if he is standing by to make a
dive. However, the helmet itself must always be
the last thing put on before the diver enters the
water. Everything else must be ready to go be-
fore the diver puts the helmet on so he won’t have
to support the weight of the helmet while out of
the water.
Fig. 2.29 Be sure to attach the umbilical to the
2.8.2 ATTACHING THE UMBILICAL TO THE HAR- diver’s harness to avoid a direct pull on the helmet.
NESS

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 is now ready to enter the water. He


should be assisted to the water if needed. If a
welding lens is being used, make sure it is hinged
up all the way if the diver is making a jump entry.

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SUPERLITE-17
2.9 EMERGENCY PROCEDURES
2.9.1 FLOODING
In the event of partial or complete flooding, the
diver may clear the helmet quickly by getting the
helmet in an upright position (normal swimming
or working position) and activating the defogger
control knob (34) or by pressing in on the manual
purge button in the center of the regulator cover.

The main helmet exhaust valve (or water dump)


Fig. 2.30 Be sure to check the communications (149-152) is located at the bottom front of the
again once the diver has donned the helmet. SuperLite-17. The opening in this valve is much
larger than the opening in the regulator exhaust
We do not recommend jump entries. A quick valve and provides a rapid means of purging the
overall inspection by the tender is done and the helmet.
diver is given the OK.
After clearing, cautiously check for additional
2.8.7 WATER ENTRY AND DESCENT flooding. If the helmet continues to take on wa-
The tender must make sure there is a sufficient ter, return to the diving station, swimming with
length of umbilical clear if the diver is using a the exhaust valve positioned at the lowest part of
jump entry. There must be no chance of the um- the hat: that is with the diver’s face forward and
bilical hanging up when the diver jumps. Also, slightly up. Keep the free flow knob on. This
the defogger valve must be turned on to overpres- increases the air/gas pressure slightly inside the
sure the helmet to prevent the possibility of wa- hat and keeps the water out. Any incoming water
ter pressure inverting the helmet exhaust valve is automatically ejected.
when hitting the water. 2.9.2 INHALATION RESISTANCE

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.

PAGE 24 Docu# 010502002


SUPERLITE-17
Immediately return to the diving station using the WARNING: Never remove the div-
emergency breathing supply. Avoid making a ing helmet while you are in the stage. If
rapid ascent if at all possible. you fall out of the stage with the helmet
off but still attached to your harness it
DANGER: Rapid ascent is dan- may be very difficult to swim. Drowning
gerous. It can lead to air embolism or may result.
decompression sickness. Air/gas embo-
lism can cause immediate loss of con- 2.10.2 REMOVING THE SUPERLITE-17
sciousness and/or death. Even on a no
decompression dive, a rapid ascent may On the SuperLite-17, you must first remove the
cause decompression sickness. A diver safety pin before you can remove the helmet.
must only make a rapid ascent when he Squeeze the pin until you can disengage it from
is in immediate danger of death by the latch catch assembly. Slide the pin out and
drowning or asphyxiation. away from the latch catch.

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.

2.9.4 DEMAND REGULATOR FREE FLOW


If the demand regulator free flows, adjust the knob
(120) in (clockwise) until it stops. If it cannot be
stopped, and the flow is strong, the dive should
be stopped. Even if there is no serious problem to
the diver, communications will be very poor.

2.10 POST DIVE PROCEDURES


2.10.1 REMOVING THE EQUIPMENT
After the diver is well clear of the water he may
remove the helmet. If the diver is working out of
a stage he must not remove the helmet until the
stage is on deck. Fig. 2.31 Carefully remove the neck dam.

Docu# 010502002 PAGE 25


SUPERLITE-17
Reach behind the back of the helmet with either
hand and lift the rear hinge tab (26) off the align-
ment sleeve (88) in the back of the helmet. Reach
underneath 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.

Reach in and spread the neck dam, pulling against


the sides of the neck dam with the palms of both
hands. Lift the neck dam over your head. Slide
the yoke backwards away from your neck to re-
move it. The diver’s harness and bail-out bottle
is then removed.

2.10.3 STORAGE OF THE HELMET BETWEEN


DIVES

If the helmet is not going to be used for a period


of time, the head cushion, should be removed.
The head cushion must be dried and replaced in
the hat before storage. The regulator adjustment
knob must be unscrewed all the way out (coun-
terclockwise) until the next dive. When the hel-
met is completely dry, or the diver is ready to
leave the job, the helmet must be stored in the
carrying bag to protect it.

Always replace the yoke/neck clamp on the bot-


tom of the SuperLite-17 to protect the bottom edge
of the helmet from damage.

If the head cushion becomes wet it may be dried


out by removing it from the helmet, squeezing
excess water out, and letting the head cushion
hang dry or putting it in a clothes drier.

WARNING: Use only the air dry


setting when drying head cushion foam
in a drier. Use of a higher setting could
cause the foam to melt or start a fire.

PAGE 26 Docu# 010502002


SUPERLITE-17

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.

3.2 COMMUNICATIONS MALFUNCTION

SYMPTOMS PROBABLE CAUSE REMEDY

No sound at either com box or Activate switch and adjust


Communication box not on.
helmet. volume.

Communications incorrectly
Switch terminal wires.
hooked up.
Plug into terminals.
Communications not hooked up.

Communicator not functional. Replace communicator.


Clean terminals (154) with
Communications weak or Terminals in helmet covered
wire brush to bright, shiny
broken up. with corrosion.
metal.

Communications only work Splice wire if damage is minor.


Break in diver's communication
when wire is wiggled back and Replace wire if damage is
wire.
forth. major.
If connector is suspect,
Communications only work
Break in waterproof remove from line and test line
when connector (158) is
connector. for integrity prior to replacing
wiggled back and forth.
connector.

Diver speech weak or not Replace microphone as per


Microphone in helmet dead.
working. manual. (Section 7.8.3 )
No sound at either
Communicator not functional. Replace communicator.
communicator or helmet.

Docu# 010502002 PAGE 27


SUPERLITE-17

3.3 ONE WAY VALVE MALFUNCTION

SYMPTOMS PROBABLE CAUSE REMEDY

One way valve (68) allows Disassemble valve, clean, and


Foreign matter in valve.
back flow. rebuild. (Section 6.2)

Disassemble valve, clean, and


One way valve doesn't flow any
Foreign matter in valve. rebuild.
gas .

3.4 SIDE BLOCK MALFUNCTION

SYMPTOMS PROBABLE CAUSE REMEDY

Defogger valve can't be shut


off. Helmet free flows through Seat assembly (41) damaged. Replace seat assembly.
defogger.
Defogger valve will not flow Turn air on to diver's supply
No air in umbilical.
gas. topside.
Defogger valve will not flow Foreign matter in side block Disassemble side block and
gas. (43a/b), or one way valve (68). clean.
Defogger valve knob (34) hard
Valve stem (40) bent. Replace valve stem.
to turn.

PAGE 28 Docu# 010502002


SUPERLITE-17

3.5 DEMAND REGULATOR MALFUNCTION


SYMPTOMS PROBABLE CAUSE REMEDY

Regulator (138a/b) Adjustment knob (120) not


Screw in adjustment knob.
continuously free flows. screwed in.

Adjust supply pressure lower


Supply pressure too high.
than 225 P.S.I.

Regulator out of adjustment. Adjust regulator.


Regulator (138a/b)
continuously free flows when Neck dam (2) turned down. Neck dam must be turned up.
underwater only.

Hair caught between base of


helmet (92) and yoke/neck Clear hair out.
clamp.
Neck dam torn. Repair or replace neck dam.
Adjustment knob screwed too
Regulator is hard breathing. Screw adjustment knob out.
far in.
Increase supply pressure to
Regulator does not supply gas. Gas supply pressure too low. minimum of 115 PSI over
ambient.
Regulator is out of adjustment. Adjust regulator.
Turn diver's gas supply on
No gas in umbilical.
topside.
Disassemble regulator, clean,
Blockage in breathing system.
and adjust.

Docu# 010502002 PAGE 29


SUPERLITE-17

3.6 WATER LEAKAGE INTO HELMET

SYMPTOMS PROBABLE CAUSE REMEDY


Water dump valve (150)
Water leakage into helmet. Seat or replace valve.
damaged or stuck open.
Exhaust valve (137) damaged or
Seat or replace valve.
stuck open.
Waterproof connector O-ring Replace O-ring.
(159) extruded or damaged.
Diaphragm (122) damaged or
Seat or replace diaphragm.
not seated properly.
O-ring (80) at base of helmet Replace O-ring.
damaged or missing.
Port retainer screws (104) loose. Tighten screws.
Neck dam (2) torn. Replace neck dam.

Hair caught between base of


Remove hair from this space
helmet (92) and yoke/neck
clamp.

3.7 EMERGENCY VALVE MALFUNCTION

SYMPTOMS PROBABLE CAUSE REMEDY

Bail out bottle drained


Stem (51) fails to seat in valve
without diver opening valve Replace valve body.
body (50).
(58).

Leaking over-pressure valve on


Service valve.
bail-out regulator.

Leaking bail-out regulator on


Service regulator.
bottle.

Stem (51) difficult to turn. Stem (51) bent. Replace stem.

Disassemble, clean,
Valve (58) will not flow gas. Foreign matter in valve.
reassemble.

PAGE 30 Docu# 010502002


SUPERLITE-17

SECTION 4.0

INSPECTION MAINTENANCE TIMETABLE FOR


SUPERLITE-17
The following service intervals are recommended minimums for helmets being used under good
conditions. Helmets used in contaminated water, burning or welding operations, or heavy jetting
must be serviced more frequently.

4.1 DAILY MAINTENANCE


See Section 5.4 for details of 4) Replace communications set (74).
daily maintenance. Order DSI Part #515-030.
See Section 7.8.
4.2 MONTHLY MAINTENANCE
See Section 5.5 for details of 5) Replace whisker rubber (139).
monthly maintenance. See Section 6.10.

4.3 EVERY SIX MONTHS OR 6) Replace main exhaust valve (150).


200 OPERATING HOURS See Section 6.11.
1) Replace inlet valve (134) and nut (126).
See Section 6.8. 7) Replace waterproof connector (158).
See Section 7.8.5.
2) Replace communications set (74).
See Section 7.8. 8) Replace O-rings
(80, 159, 143, 81, 106, 105).
4.4 YEARLY OR 400 OPERATING HOURS
1 ) Rebuild side block assembly (order 9) Replace oral nasal valve (84).
Side Block Rebuild Kit, DSI Part # See Section 6.9
525-311, for all SuperLite helmets and
KMB Band Masks). See Section 6.3. 10) Replace oral nasal (83).
See Section 6.9.
2) Rebuild demand regulator assembly
(order Regulator Repair Kit, DSI Part 11) Replace neck dam (2).
#525-309, for all SuperLite helmets and See Section 7.9.4.
KMB Band Masks.) See Section 6.8.
12) Test Port Retainer Inserts
3) Rebuild one way valve (order One Way (this is a dealer provided service)
Valve Repair Kit, DSI Part #525-330.
This kit is included in the Side Block kit
DSI Part # 525-311.) See Section 6.2.

Docu# 010502002 PAGE 31


SUPERLITE-17

NOTES

PAGE 32 Docu# 010502002


SUPERLITE-17

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.

Fig. 5.1 - Tools required to do proper maintenance


on the SuperLite-17.
5.2 R EQUIRED T OOLS , C LEANING A GENTS ,
LUBRICATION 1/4 inch flat blade screwdriver
Every diver should carry sufficient tools and 3/8 inch flat blade screwdriver
spare parts to maintain his helmet in top #2 Phillips blade screwdriver
working condition. It is very important to 7/64 inch allen wrench driver
use wrenches of the correct size rather than 9/64 inch allen wrench driver
adjustable wrenches when possible. Adjust- 5/32 inch allen wrench driver
able wrenches tend to slip and can round the
edges of soft brass parts. The following Open end wrenches in the following sizes:
wrenches and tools are required to maintain 3/8 inch
the SuperLite-17: 7/16 inch
9/16 inch
Torque wrench with the following attach- 3/4 inch
ments: 7/8 inch
1 3/8 inch socket 1 inch
7/16 inch open end wrench
9/16 inch open end wrench Two adjustable wrenches 6 and 8 inches in
5/8 inch open end wrench length.
11/16 inch open end wrench 3/8 inch flat blade screwdriver with a notch
3/4 inch open end wrench in the center of the tip.
13/16 inch open end wrench 1/4 inch flat blade stubby screwdriver
7/8 inch open end wrench 2 needle nose pliers
1 inch open end wrench diagonal cutting pliers
slip joint pliers
Torque screwdriver with the following at- 3/32 inch punch
tachments: putty knife
1/8 inch flat blade screwdriver O-ring removal tool

Docu# 010502002 PAGE 33


SUPERLITE-17
DSI regulator repair tools: DANGER: The standard SuperLite-
D.S.I. Part #525-620 17 Is not intended for oxygen service as it
ballpeen hammer comes from the factory. If the user in-
11 inch by 3/16 inch tie wraps: tends to use this helmet for such service,
DSI Part # 520-042 all parts must be cleaned for oxygen
Silicone grease safety, oxygen compatible O-rings must
Loctite® 222 Threadlocker be installed, and lubrication with an oxy-
#320, 400, 600 wet/dry sandpaper gen safe lubricant must be maintained.
rubbing compound Only lubricants such as Krytox® or Halo-
automotive wax carbon® are acceptable for oxygen ser-
rags vice.
To clean parts heavily encrusted with salt we DANGER: In-water decompression
recommend a dilute solution of white vin- with oxygen is a specialized procedure.
egar and a toothbrush. All parts of the diving system must be ox-
ygen compatible and cleaned for oxygen
Lubrication for air diving should only be service. Any part of the system (i.e., mani-
done with food grade silicone grease. If aero- folds, hoses, fittings, etc.) which are ex-
sol silicone is used, take care to prevent it posed to compressed air must be consid-
from coming into contact with the face port, ered contaminated and not be used again
or any plastic parts. until cleaned for oxygen service.

DANGER: All parts on the


SuperLite-17 must be adjusted to their 5.3 GENERAL
proper torque specifications. See Appen- Each diver must establish his own minimum
dix 1 for a complete listing of torque standards for the care of his helmet. We
specifications for each part. Failure to offer recommendations here with the sug-
adjust parts to the recommended specifi- gestion that the diver establish for himself
cations could lead to helmet failure and what is necessary to provide a good working
accidents. This could be fatal. unit. Use of the helmet in fresh water will
require a timetable for maintenance pro-
cedures different from that when the helmet
DANGER: Never use any aerosol is used in salt water. Using the helmet in sea
propelled sprays near the face port of the water while jetting in sand will necessitate
SuperLite-17. The Freon propellent used increased maintenance. Use of the helmet in
in these aerosols can invisibly damage a heavy oil environment or other chemicals
the face port and cause it to shatter upon will make it necessary to replace rubber
impact from any strong blow. If the face parts whenever necessary to assure proper
port fails underwater the helmet will flood function.
and drowning may result.

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SUPERLITE-17
5.4 DAILY MAINTENANCE

LUBRICATION:
Silicone Grease

The following steps must be performed daily


at the completion of diving operations.

1) Disconnect the helmet from the diving


hose and bail-out bottle. Make sure the air is
off and the breathing system of the helmet is
unpressurized. To vent the system, open the
free flow valve knob (34) and emergency
valve knob (55) until all gas flow stops.

WARNING: Never disconnect any


hose from the helmet unless all gas has
been vented from the hose first. If the
hose is disconnected with pressure in the
line the fittings may be damaged. In addi- Fig. 5.2 Cover the air inlet and emergency valve
tion, the hose can whip about causing openings with dust caps when not in use.
injury to anyone standing nearby.

2) Place a protective cap over both the air


inlet (67) and the emergency valve inlet (50)
to prevent foreign matter from entering the
valves.

3) If the head cushion is wet, remove it from


the helmet and rinse it with fresh water. The
head cushion is fastened into the helmet
with snap tabs and pulls out easily. To
ensure that the head cushion is dry for future
use you may want to remove the head cush-
ion foam. However, do not remove the foam
unless it is absolutely necessary. It will dry
properly without removing the foam.

4) Rinse the helmet thoroughly with fresh


water. Turn the free flow valve knob, emer-
gency valve knob, and regulator adjustment
knob (120) while rinsing to prevent salt from
accumulating under these valves. Run water
under the regulator cover (123), and in the
regulator body (112) through the air deliv- Fig. 5.3 Remove the head cushion.
ery tube located in the oral/nasal (83).

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SUPERLITE-17
5) Remove the earphones (71,72) from the
retainer clips (147) so they can dry com-
pletely. Avoid getting water on the oral/
nasal microphone and earphones. Remove
the earphone covers from the earphones so
they can dry completely.

6) Wipe the inside of the helmet out with a


clean, damp rag. Do not depress the purge
button while rinsing the regulator as this
action will permit foreign matter back into
the inlet valve and seat.

7) Rinse the yoke/neck clamp assembly sepa-


rately from the helmet. Operate the neck
clamp and actuate the latch catch mecha-
nism as you run fresh water over them.

8) Screw the demand regulator adjustment


knob all the way out, away from the regula-
tor body. This will prolong the life of the
inlet valve seat on the valve stem (134) and
keep the internal adjustment correct.
Fig. 5.4 Remove the foam from the headcushion if
it is wet.

Fig. 5.5 Rinse the helmet with fresh water.


Fig. 5.6 Remove the earphones from their
retainers.

PAGE 36 Docu# 010502002


SUPERLITE-17
9) Lubricate the shaft of the nose block
device (86) with silicone grease.

10) Remove the o-ring (80) from the base of


the helmet, clean and lubricate.

11) If the neck dam is damaged (2) it must


be replaced.

5.5 MONTHLY MAINTENANCE


(OR BETWEEN JOBS)

5.5.1 YOKE/NECK CLAMP ASSEMBLY


Inspect the neck dam (2) carefully. There
must be no holes in the neck dam, and the
neoprene should be firm. Do not patch the
neck dam.

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.

The neck clamp (7) must operate


smoothly and easily. If it is bent or out of
alignment, it must be returned to Diving
Systems International for repair, or be re-
placed.

5.5.2 HELMET O-RING


Inspect the o-ring (80) on the base of the
helmet. It must be in good condition with no
nicks, tears, or cracking. Replace the o-ring
if it shows signs of wear.

5.5.3 HEAD CUSHION


Remove the foam from the head cushion (1)
and inspect it for wear. If the foam is worn or
crumbling it must be replaced (order DSI
Part #510-523).
Fig. 5.8 Remove the o-ring from the base of the hat
to lubricate it.

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SUPERLITE-17
5.5.4 COMMUNICATIONS INSPECTION
Visually inspect the earphones (71,72), mi-
crophone (73), wires, lugs, and communi-
cations posts (154). Test each component
for proper operation. Connect to the deck
amplifier and talk back and forth. Replace
any weak earphone or microphone.

Open the earphone rubber covers and re-


move the protectors. Allow to dry thor-
oughly. Replace defective earphones.

5.5.5 LUBRICATE NOSE BLOCK O-RINGS


Tools Required:
7/16 inch Open End wrench

1) Unscrew the nose block device packing


nut (107) and lubricate the two o-rings (106)
and main shaft (86). Retighten the nut just to
the point where the nose block device will
still slide, but it requires a firm push or pull.

Test the shaft to ensure that it will still slide


freely at this time. If it does not, loosen or
tighten the nut (107) just enough to permit
the shaft to slide properly.

To lubricate the nose block o-rings you must


loosen the nut.
PAGE 38 Docu# 010502002
SUPERLITE-17

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.

6.2 ONE WAY VALVE


6.2.1 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


assembly (68):
Fig. 6.1 Remove the one way valve from the side
1) The one way valve assembly must be removed block.
from the side block (43a/b). Use the open end As the seat is removed, the wiper (65) and the o-
wrench to remove it. ring (64) slide out in place in a groove on the
seat. The poppet (62) and the poppet o-ring (63)
2) After the one way valve has been removed, usually come out in the seat being followed by
use two wrenches or hold the hex part of the body the spring (61). The only functional part remain-
(60) in a soft jaw vise while removing the seat ing in the valve body is a non-moving, pressed-
(66) with a wrench. in cage. The function of the cage is to prevent the
poppet o-ring from blowing out of place during
CAUTION: Do not use pliers on the high flows.
main body of the one way valve. You may
damage the valve if pliers are used. 3) Inspect the body interior for foreign matter of
any type and clean, if necessary.
Docu# 010502002 PAGE 39
SUPERLITE-17

adapter
seat
wiper o-ring
o-ring
poppet
spring
valve body
o-ring

Fig. 6.2 Blow-apart of the non-return valve.

4) Inspect the seat, wiper, o-ring, poppet o-ring


and poppet for wear, replace if necessary. Be sure
each part is clean. A repair kit is available for
replacement parts. (DSI Part #525-330)

5) Place silicone lubricant on the components,


then wipe clean with a non-lint producing cloth.
Be careful to wipe the poppet and poppet o-ring
thoroughly, removing nearly all silicone to pre-
vent foreign materials from sticking to these com-
ponents.

6) Inspect the spring and clean or replace if nec-


essary.

6.2.2 REASSEMBLY OF THE ONE WAY


VALVE
1) Slide the new o-ring (63) over the poppet (62). Fig. 6.3 The one way valve is easily disassembled
for cleaning.
2) Insert the new spring (61) into the valve body
(60), followed by the poppet. CAUTION: Use two wrenches or
hold the hex part of the body in a vise
3) Next, install the new o-ring (64) and new wiper while removing or turning the seat with a
(65) on the seat (66). Thread the seat into the valve wrench. Do not use pliers on the main
body. body of the one-way valve. You may dam-
age the valve if pliers are used.
4) Tighten the seat to 240 inch lbs. with a torque
wrench while holding the body in a soft jaw vice 5) If the adapter (67) has been removed, it must
or wrench. be wrapped with Teflon tape on the tapered pipe

PAGE 40 Docu# 010502002


SUPERLITE-17
threads and reinstalled at this time. Hold the one On the SuperLite-17B, the bent tube assembly
way valve in the vice and tighten the adapter. (45b) must be entirely removed before removal
of the side block assembly is started. On the Su-
DANGER: Do not allow Teflon tape perLite-17A it is only necessary to release the hose
to cover the end of the adapter, or to en- (45a) from its connection with the regulator (138a/
ter the one-way valve. Loose pieces of Te- b)
flon tape can interfere with the perfor-
mance of the one-way valve or regulator 6.3.2.1 REMOVAL OF BENT TUBE
and may block the diver’s air supply. This ASSEMBLY
could lead to death through suffocation.
1) Completely unthread the bent tube assembly
6) Test the operation of the valve. nut (45b) from the side block.

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).

The side block assembly is held in place on the


helmet shell by a stud, flat washer, lock washer,
nut, and a machine screw. The screw does some
securing but its main function is to prevent rota-
tion of the side block. The stud also extends into
the interior of the helmet shell far enough to se-
cure the air train by means of a washer and nut.
The air train cup that fits over the stud is made of
soft brass and cannot be used for a bearing sur-
face to mount the side block. RTV silicone rub-
ber compound is used to form a gas tight seal
between the side block and the exterior of the
helmet shell.

6.3.2 SIDE BLOCK ASSEMBLY REMOVAL

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.

Docu# 010502002 PAGE 41


SUPERLITE-17
4) The side block assembly (39) is ready to start 6.3.3 SEPARATING THE SIDE BLOCK
removal. ASSEMBLY FROM THE HELMET SHELL
6.3.2.2 DISCONNECTING THE HOSE Tools Required:
ASSEMBLY Putty Knife
7/16 inch Open End Attachment on Torque
1) Use a back-up wrench to hold the inlet nipple Wrench
(130a) on the regulator (112). 1/4 inch Flat Blade Stubby Screwdriver

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.

Fig. 6.5 Disconnect the hose at the regulator.


Fig. 6.6 Remove the nut that secures the air train.

3) The stud nut (98) is removed next, with the


lock washer (97) and flat washer (96).

4) Next, the alignment screw (102) is removed.

5) The side block assembly is now unfastened,


but held in place by the rubber sealing compound
(silicone sealant) that acts as a glue. It may be
necessary to rock just slightly, or pry the side

PAGE 42 Docu# 010502002


SUPERLITE-17

Fig. 6.9 Use a putty knife to separate the block


from the helmet shell.

block from the helmet shell. A thin putty knife


can be pushed between the side block and the
helmet shell to help free it. Do not use a screw-
driver or chisel as damage to the shell could re-
sult. Be sure to peel or scrape the old silicone
Fig. 6.7 Remove the nut from the stud. sealant away from both sealing surfaces before
reassembling. Acetone helps remove this, but
must be used sparingly since it will also remove
the 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.

Fig. 6.8 Remove the screw that threads into the


block.
Docu# 010502002 PAGE 43
SUPERLITE-17
6.3.4 SIDE BLOCK ASSEMBLY 4) Tighten the screw (102) to the correct torque.
REPLACEMENT See Appendix 1 for torque specs.

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.

DANGER: If silicone sealant is


blocking the air flow into the helmet it
must be cleaned out. If it is not the diver
may not be able to properly defog the
helmet or clear a flooded helmet quickly.
In addition, if the demand regulator is not
delivering air properly, the diver cannot
use the free flow system as a source of
breathing gas.

Fig. 6.10 Apply silicone sealant to the side block


prior to reassembly.

WARNING: Do not dive the helmet


until the sealant has had time to cure.
Check the directions on the tube of seal-
ant for curing time. If the helmet goes into
the water before the sealant has cured it
could leak through the side block mount-
ing stud hole, screw hole, or air flow hole.

2) Thread the screw (102) through the helmet


shell (92) and lightly tighten into the side block
body.

3) Slide the flat washer (96) and the lock washer


(97) onto the stud (42). Run the stud nut (98)
down the stud and tighten. DO NOT OVER-
TIGHTEN. See Appendix 1 for torque specs.

PAGE 44 Docu# 010502002


SUPERLITE-17
6.4 DEFOGGER VALVE
6.4.1 DISASSEMBLY OF THE DEFOGGER
VALVE

Tools Required:
3/8 inch Slotted Flat Blade Screwdriver
13/16 inch Open End Attachment on Torque
Wrench

The defogger valve components are disassembled


as follows: Fig. 6.11 Remove the nut and spring.

1) First, unscrew the lock nut (32) and remove


the spring (33), control knob (34), and washer
(35).

2) Next, unscrew the bonnet (36). Its o-ring (37)


will come off with it. The valve stem (40), o-ring
(39), and washer (38) usually come out with the
bonnet and can be pushed out of the bonnet once
removed from the side block body.

3) If the stem remains in the side block body it


can be lifted out after the bonnet is removed. Fig. 6.12 Remove the bonnet from the side block.

4) The seat assembly (41) can be unscrewed from


the side block body with the stem or a screwdriver.

non-return valve body


side block body
emergency valve body
stud

poppet defogger valve handle

seat assy.
emergency valve handle
bonnet

valve stem

low pressure plug


bent tube
Fig. 6.10 Components of the “B” side block, including the one way valve and emergency valve.

Docu# 010502002 PAGE 45


SUPERLITE-17
6.4.2 CLEANING AND LUBRICATING

1) Clean all the metal parts in a 50/50 dilute solu-


tion of white vinegar/water. Rinse in fresh water.

2) Check the Teflon® seat (41) for wear, and re-


place if necessary.

3) The Teflon® washer (38) and o-ring (39) must


be replaced if worn. Replace the o-ring (37) if
Fig. 6.13 Separate the shaft from the bonnet. worn.

4) Be sure to place a light coating of silicone


grease on all internal moving parts, o-rings, and
washers. However, do not lubricate the teflon seat,
as this will attract dust and debris.

Fig. 6.14 The “A” side block uses the same


internal parts as the “B”.
Fig. 6.15 Check the seat for wear.

Fig. 6.16 Check the o-ring and teflon washer.


PAGE 46 Docu# 010502002
SUPERLITE-17
6.4.3 REASSEMBLY OF THE DEFOGGER
VALVE
Tools Required:
3/8 inch Slotted Flat Blade Screwdriver
13/16" Open End Attachment on Torque Wrench

1) Screw in the new seat assembly (41) until it is


even with the front of the side block body (43a/
b).

2) Next, install the new Teflon® washer (38) and


new o-ring (39) onto the stem (40).
Fig. 6.18 Don’t forget to install the washer before
installing the valve knob.
3) Insert the proper end of the stem into the seat
assembly and turn clockwise until the seat lightly 5) Slide the bonnet over the stem and thread the
bottoms out. Leave the stem in place. bonnet into the side block.

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.

7) Place the new Teflon® washer (35) and the con-


trol knob (34) on the stem (40) and rotate the stem
counterclockwise until the seat assembly (41) tops
out fully open. The control knob must turn
smoothly without any binding. Binding (or “hard
spots”) in the rotation could be an indication of a
bent stem that must be replaced.

8) Install the spring (33), and locknut (32). Screw


on the locknut until it is flush with the knob.

Fig. 6.17 Be sure to tighten the bonnet to the


proper torque value.
Docu# 010502002 PAGE 47
SUPERLITE-17
6.5 EMERGENCY VALVE ASSEMBLY
The emergency valve assembly is not built into
the side block. It is a separate component that
can be removed and replaced, or disassembled in
place on the side block assembly. The emergency
valve control knob is not interchangeable with
the defogger valve control knob.

6.5.1 DISASSEMBLY OF THE EMERGENCY


VALVE ASSEMBLY

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

1) Remove the lock nut (57), spring (56), and knob


(55).

Fig. 6.20 Remove the knob.

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.

3) Inspect the stem seat (51) for unevenness or


wear and replace if necessary. It must also be re-
placed if the stem is bent.

4) Check the seat in the emergency valve body


(50) for wear or unevenness. Replace the body if
necessary.

5) To remove the emergency valve body from the


side block (43a/b) the one way valve assembly
(69) must first be removed.
Fig. 6.22 Remove the valve stem.
6.5.3 REASSEMBLY OF EMERGENCY VALVE
Tools Required:
11/16 inch Open End &1 inch Open End Torque
Wrench Attachments & Torque Wrench
3/8 inch Slotted Flat Blade Screwdriver
Soft jaw vice

NOTE:
The emergency valve does not have to be removed
from the side block to be rebuilt.

1) With the exception of the tapered pipe thread


end of the emergency valve body (50), lubricate
all components with a light coating of silicone
grease.

2) Place the new Teflon® washer (52) and new


packing (53) on the stem (51). NOTE: There are
two different packings and washers supplied in
the kit, for rebuilding both the older style and the
newer high flow emergency valve. Match the re-
moved packing and washer to the new ones sup-
plied and discard the others.

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.

Fig. 6.24 Wrap the pipe threads with pipe tape


prior to reinsalling the valve body.

4) Rotate the stem until it is seated all the way in.

5) Thread the packing nut (54) onto the body. Run


the nut in and tighten slightly with a wrench.

6) Place the knob (55) onto the stem and rotate


the stem all the way out, then back again. The
rotation must be smooth. If “hard spots” or un-
evenness are felt during the rotation, the stem may
be bent and could need replacement. Fig. 6.25 Tighten the nut to complete the assembly.

7) Tighten the packing nut with a wrench until


moderate resistance is felt when turning the knob.

8) Place the spring (56), and locknut (57) onto


the stem securing the knob.

9) Tighten the locknut until it is flush with the


knob. The assembly is now complete and ready
for testing.

10) Test the valve by attaching it to an emergency


air supply source. There must be no leakage of
gas. Turn on the bail-out bottle and leave it on for
several hours. There must be no drop in pressure
in the system if the valve is operating properly.

PAGE 50 Docu# 010502002


SUPERLITE-17

6.6 BENT TUBE ASSEMBLY


6.6.1 GENERAL
The bent tube assembly (47b) provides for breath-
ing gas flow from the side block assembly to the
regulator assembly on the SuperLite-17B. Both
ends of the bent tube assembly disconnect for
complete removal.

6.6.2 REMOVAL OF THE BENT TUBE


ASSEMBLY

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

1) Always start removal at the side block end.


The free swiveling mount nut on this end of the
bent tube can be unthreaded completely and can
slide down the tube. Fig. 6.27 Loosen the jam nut.

Fig. 6.26 Always start removal of the bent tube


assembly at the side block end. Fig. 6.28 Remove the bent tube.

Docu# 010502002 PAGE 51


SUPERLITE-17
2) The regulator end has a jam nut (131b) that 6.6.4 REPLACEMENT OF BENT TUBE
locks the mount nut in place. With one wrench, ASSEMBLY
hold the bent tube mount nut. With another
wrench, turn DOWN the jam nut, backing it away If a new bent tube is being installed or the side
from the mount nut. The mount nut can then be block has been removed, refer to the manual for
rotated until free of the regulator inlet nipple installation instructions.
(132b) threads. It can be pushed up the bent tube.
Tools Required:
3) With the two mount nuts free, the bent tube 11/16 inch Open End Torque Wrench Attachment
assembly can be pulled straight out of the regula- 7/8 inch Open End Torque Wrench Attachment
tor inlet nipple. The bent tube assembly can be 7/8 inch Open End Wrench Wrench
rotated back and forth to aid removal. Be careful
to only rotate and pull straight out of the inlet 1) Replace the o-ring (46b) at the regulator end
nipple. DO NOT BEND THE TUBE. and the Teflon® washer (44b) at the side block
end with the new ones supplied.
6.6.3 INSPECTION OF BENT TUBE
ASSEMBLY 2) Push the o-ring end of the bent tube assembly
into the regulator inlet nipple (132b). Slide it in
The o-ring at the regulator end (46b) is inspected until the side block end is aligned with the threads
and replaced if necessary. The Teflon® o-ring for the mount nut.
(44b) at the side block end is inspected and re-
placed if necessary. 3) Be sure the Teflon® o-ring is in place.

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.

6) Hold the nut on the end of the bent tube with a


wrench and tighten the jam nut (131b) against it
with another wrench. The bent tube nut must not
be bottomed out against the nipple.

Fig. 6.29 Inspect all of the components of the bent


tube carefully.

PAGE 52 Docu# 010502002


SUPERLITE-17
6.7 HOSE ASSEMBLY
The hose assembly (47b) provides for breathing
gas flow from the side block assembly to the regu-
lator for the SuperLite-17A. Both ends of the hose
assembly disconnect for complete removal.

Fig. 6.31 Remove the o-ring very carefully to


avoid damage to the fitting.

6.7.3 O-RING REPLACEMENT


Fig. 6.30 The hose assembly is only used on the 1) Remove the o-ring (44a) from the side block
SuperLite-17A. end of the hose assembly by pinching it with your
fingers and sliding it up the threaded end of the
6.7.1 HOSE ASSEMBLY REMOVAL assembly. Install a new o-ring that has been lu-
bricated with DC-111 lubricant.
Tools Required:
9/16 inch Open End Wrench
2) To remove the o-ring (46a) on the regulator
11/16 inch Open End Wrench
end of the hose you will need to use a dental tool
13/16 inch Open End Wrench
or bent wire. Care must be taken not to damage
O-ring Removal Tool
the sealing surface on the hose fitting when re-
moving the o-ring. If the fitting is gouged it will
leak breathing gas.
1) Loosen the hose assembly (47a) at the regula-
tor end first, while holding the regulator inlet
6.7.4 HOSE ASSEMBLY REPLACEMENT
nipple (130a) with a second wrench.
1) Thread the hose assembly into the side block
2) Disconnect the hose from the inlet nipple.
and tighten with a wrench to the proper torque
specification.
3) Loosen the hose where it connects to the side
block (43a).
2) Install the hose assembly fitting onto the end
of the regulator inlet nipple (130a). Tighten the
4) Disconect the hose from the side block.
fitting while holding the nipple with a second
wrench.
6.7.2 HOSE ASSEMBLY INSPECTION

Inspect the hose for gouges, cuts, or blisters. If


the hose is worn or damaged it must be replaced.
Inspect the o-rings (44a, 46a). If they are worn or
cracked they must be replaced.

Docu# 010502002 PAGE 53


SUPERLITE-17
6.8 DEMAND REGULATOR For the gas inlet valve and adjustment system to
operate properly, the components in the demand
The regulator system on all Kirby Morgan hel- regulator MUST be in good condition and MUST
mets is simple and highly reliable. Even if the be periodically adjusted internally.
components are not in good condition, the regu-
lator will probably continue to function. How- Four special tools, the inlect valve holder (DSI
ever, inhalation resistance will be extremely high Part #525-616), the regulator adjustment wrench
if the demand regulator is not maintained prop- (DSI Part #525-611), the socket wrench (DSI Part
erly. There is always the backup supply of steady #525-612), and the castle wrench (DSI Part #525-
flow gas from the defogger valve in the event the 618) should be used to work on the regulator
demand regulator functions too badly. The point whenever possible.
here is that the demand regulator must receive
regular maintenance to assure the best perfor- Disassembly, assembly, and adjustment can be
mance possible. done without these tools, but the work is much
easier and the adjustment is better if these tools
If the regulator does not breathe easily, the diver are used. The above 4 tools are available together
cannot work hard and will tire rapidly. Simply along with a tool pouch. The “Tool Kit with
put: If the demand regulator does not work prop- pouch” is DSI Part #525-620.
erly the diver cannot work properly. This makes
the maintenance of the demand regulator assem- 6.8.1 DEMAND REGULATOR TEST FOR
bly essential. CORRECT ADJUSTMENT, FULLY
ASSEMBLED

Check the regulator for adjustment and proper


function with the assembly complete and the
breathing gas supply on.

1) Press the purge button in the cover (123) to


check flow. There should be between 1/16 inch
and 1/8 inch free travel in the button, then the gas
must start flowing. When the button is fully de-
pressed, a strong surge of gas must result.

2) Run the adjustment knob (120) out until a


steady flow of gas is present.

3) Run the adjustment knob in until the free flow


just stops. If the flow does not stop, check the
supply pressure. If it is correct, the regulator needs
internal adjustment.
Fig. 6.32 The regulator tool kit will help you get
4) Don the neck dam/yoke assembly and helmet
the maximum performance from your regulator.
and test breathe the helmet to check for resistance.
If the adjustment knob has been set in Step #3
above and the regulator breathes hard, internal
adjustment is necessary.

PAGE 54 Docu# 010502002


SUPERLITE-17
6) When no supply pressure is going to be on the
helmet for several hours or more, the regulator
adjustment knob (120) must be backed all the way
out. This will prolong the life of the inlet valve.

6.8.2 INSPECTION OF REGULATOR BODY


INTERIOR

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.

DANGER: Do not perform this test


unless the diver is stationed right next to
the diver’s air manifold and you are cer-
tain the air is on to the manifold. If the
diver is unable to flow air to the helmet,
either through the umbilical or the bail-
out, he may not be able to remove it eas-
ily. To break the seal, the diver must reach
up and pull the neck dam away from his
neck. This will allow air to enter the hel-
met. A tender must be standing by during
this test to assist the diver if required.

Start by visually checking the regulator exhaust


valve (137) and the main exhaust (water dump)
valve (150) for correct seating. If the leak cannot
be located in the other components, and the regu-
lator is still suspect, it can be removed, (see Sec-
tion 6.8.5). With no gas supply connected, attempt
to inhale directly from the mount tube to check
Fig. 6.34 To inspect the interior of the regulator,
the regulator for leaks. A finger must be held over
you must remove the cover first.
the inlet nipple (130a/132b) during this check.
Docu# 010502002 PAGE 55
SUPERLITE-17
5) Clean the interior of the regulator body if nec-
essary. Make sure the diaphragm has no signs of
wear or aging. Do not reassemble yet. Use only
replacement diaphragms manufactured by Div-
ing Systems International, Inc. as others may not
stay securely in place.

6) Reinstall the diaphragm, cover, and clamp.


Tighten the clamp screw to the recommended
torque. See Appendix I for the proper torque
value.

6.8.3 ADJUSTMENT SYSTEM LUBRICATION

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

Fig. 6.36 Blow-apart of demand regulator


shaft
body
piston packing nut

regulator cover
exhaust valve springs

inlet valve

-N
SI
AV
D

Y
350 R

or

t
e g ula

clamp
roller lever diaphragm

PAGE 56 Docu# 010502002


SUPERLITE-17

Fig. 6.37 Remove the adjustment knob.

Fig. 6.39 Shake out the spacer spring set and


washer.
7) Inspect the o-ring (118) for cuts. Replace if
necessary.
Fig. 6.38 To remove the pin from the adjustment
knob, you need a hammer and pin punch. 8) Inspect the washer (117) for wear. Replace if
necessary.
2) Remove the nut. The adjustment shaft (94) and
the knob are unscrewed along with the nut. 9) Inspect the inside of the adjustment tube to be
sure there is no corrosion and the adjustment as-
3) Punch out the retaining pin (121) with a 3/32" sembly can travel freely.
punch. While driving the pin through, support the
adjustment end with a block of wood to avoid
bending the shaft. Be careful or damage may re- 6.8.4 REASSEMBLY OF ADJUSTMENT
sult to the adjustment shaft. SYSTEM

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).

6.8.5 DEMAND REGULATOR ASSEMBLY


REMOVAL

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

1) To remove the regulator (138a/b) from the hel-


met, the bent tube (47b) or hose assembly (47a)
must be removed first. If your helmet is the 17B,
the bent tube assembly must be removed entirely Fig. 6.41 Use a 1 3/8 inch socket to remove the
before regulator removal. If your helmet is the regulator mount nut.

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.

5) The o-ring (118) and washer (117) remain on


the shaft (116).

6) Tilt the helmet so that the spacer (115), spring


set (114), and piston (113) fall out of the adjust-
ment shaft tube.

7) Place the adjustment knob on a block of wood


and drive the retaining pin (121) out with the
punch.
Fig. 6.43 It isn’t neccessary to remove the
regulator from the helmet to adjust or tune it. 8) Remove the inlet nipple (130a or 132b) from
3) The regulator mount nut (82) is removed with the regulator body.
the sealing o-ring (81).
9) Inside the regulator body, remove the nut (126)
4) Now the regulator assembly can be pulled out from the inlet valve (134). The inlet valve must
of the helmet. be held to prevent rotation when the nut is being
unscrewed. The castle wrench may be used to
5) The whisker is held in place at the regulator hold the inlet valve while the nut is unscrewed.
body by being stretched over the regulator ex- Insert the castle wrench into the inlet nipple and
haust flange. To remove the whisker from the press it onto the inlet valve. Also, the inlet valve
regulator body stretch it off. holder tool can be used to hold the inlet valve by
inserting it through the balance hole in the inlet
6.8.6 DISASSEMBLY OF THE DEMAND tube and wedging it against the inlet valve stem.
REGULATOR These tools are included in the DSI Tool Kit, DSI
Part #525-620.
Tools Required:
1/4 inch Flat Blade Screwdriver Attachment on
Torque Wrench
DSI Regulator Tool Kit, DSI Part #525-620
7/8 inch Open End Attachment on Torque Wrench
3/4 inch Open End Attachment on Torque Wrench
3/32 inch Punch
7/8 inch Open End Wrench
Small Ball Peen Hammer

1) Remove the cover clamp screw (124) and cover


clamp (125).

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

Fig. 6.45 The inlet nipple must be in good


condition.
3) O-rings: Check for irregularities in the rub-
ber.

4) Exhaust valve: Be sure there is no curling or


deformation and that the rubber is in good shape.

5) Inspect the whisker. Replace the whisker if it


shows wear or aging. Replace the whisker if it Fig. 6.46 Replace the exhaust valve if the rubber
allows bubbles to interfere with visibility. is worn.
PAGE 60 Docu# 010502002
SUPERLITE-17
valve securely held insert it into the inlet tube in the regulator body (112). Tighten inlet nipple to
the regulator body (112). 40 inch pounds.

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.
Docu# 010502002 PAGE 61
SUPERLITE-17
6.8.10 TUNING THE REGULATOR

1) Remove clamp (125), cover (123) and dia-


phragm (122).

2) Screw (clockwise) the adjustment knob (120)


all the way in, towards the regulator body (112).

3) Pressurize the regulator to between 120 - 150


p.s.i. of supply pressure.

4) Screw the adjustment knob out until the regu-


lator starts to free flow. Screw the adjustment knob
Fig. 6.48 The whisker must be properly seated on in until the free-flow just stops and then in one
the flange of the regulator. more turn.

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.

PAGE 62 Docu# 010502002


SUPERLITE-17
11) To bend the lever down, place the disk end of
the DSI 1/4-inch wrench onto the flat area of the
adjustment tube within the regulator. Next slide
the disk, as far as possible, under the lever (106).
With your finger, bend the lever down over the
disk to the desired height. Be careful not to bend
the lever too far!

12) Replace the diaphragm and the cover. Test


the purge button. Continue until proper tolerances
are reached.

IMPORTANT NOTES ON REGULATOR Fig. 6.49 The inlet valve holder is inserted in the
ADJUSTMENT: balance hole on the inlet tube.

1) It is permissible to loosen the nut (126) no more


than l/8th of a turn to adjust the lever (128) height.
If the nut is loosened beyond this amount, the
regulator will not flow to its maximum rate due
to insufficient leverage between the lever (128)
and the inlet valve stem. If the nut is adjusted too
tight, the regulator will leak.

2) If a new inlet valve is installed, allow the regu-


lator to sit for 24 hours with the adjustment knob
(120) turned in all the way, before adjusting. This
will allow the rubber in the inlet valve stem (134)
to take a set against the inlet nipple (130a or 132b).
If the regulator is to be used immediately, be aware
that the rubber seat will take a set, changing the
adjustment and the regulators performance. This
requires the readjustment of the regulator after
use following the proper setting time and proce-
dure

3) The two opposing blades on the bottom of the


lever must be in perfect alignment with each other
and be free of nicks or burrs.

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

Docu# 010502002 PAGE 63


SUPERLITE-17
4) The adjustment knob must be backed out all
the way.

5) The inlet valve (134) must be held (to prevent


rotation) while the nut (126) is loosened. The in-
let valve holder found in the DSI regulator ad-
justment tool kit is used to hold the inlet valve.
The inlet valve holder slips into the lower bal-
ance hole of the regulator and jams the inlet valve
by exerting pressure up or down.

6) After the tool is in place, screw the adjustment


knob all the way in, then back out a few turns.

7) The regulator adjustment wrench from the DSI


tool kit is used to loosen the nut until the lever is
loose.

8) Pressurize the regulator again. If there is no


steady flow, unscrew the adjustment knob (120)
until a slight flow starts, then in until the flow
Fig. 6.51 To bend the lever down, use the disk just stops.
end of the regulator adjustment wrench.
9) Adjust the nut (126) until there is no less than
6.8.11 REGULATOR STEADY FLOWS 1/16 inch and no more than 1/8 inch play in the
WHEN PRESSURED UP, roller end of the lever.
SPECIAL TOOLS USED
10) Install the diaphragm (122) in place.
Tools Required:
1/4 inch Flat Blade Attachment on Torque Screw- 11) Press the cover (123) over the diaphragm.
driver Hold the cover tightly against the diaphragm. If
DSI Regulator Adjustment Kit, DSI Part #525- gas flow starts, the lever is too high and must be
620 bent down.

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).

15) If the purge button travel is correct, the ad-


justment is complete.

CAUTION: The nut must not be


loosened more than 1/8 turn to lower the
height of the lever. If more adjustment is
necessary the lever should be bent down-
ward. If the nut is loosened more than 1/8
turn the lever will not have enough travel Fig. 6.52 Check the flow of the regulator once
for proper flow rates. you have adjusted it using the regulator
adjustment tools. There must be between 1/16 inch
WARNING: The lock nut must al- and 1/8 inch of play in the roller end of the lever
ways be replaced if removed from the in- when it is properly adjusted.
let valve. The plastic material that locks
the nut from unscrewing is not designed 6.8.12 REGULATOR STEADY FLOWS
for multiple reuse. If the nut comes loose WHEN PRESSURED UP,
during a dive the regulator would free flow NO SPECIAL TOOLS AVAILABLE
heavily. In the situation where the diver
is using bottled breathing gas this would Tools Required:
result in a rapid consumption of breath- 1/4 inch Flat Blade Attachment on Torque Screw-
ing gas. driver
Needle Nose Pliers
2 Adjustable Wrenches

When the special tools are not available:

1) The supply gas must be turned off.

2) The inlet nipple (130a or 132b) must be re-


moved.

3) The inlet valve (134) is held in place by wedg-


ing a small screwdriver between the inlet valve
and the inside of the inlet tube, part of the regula-
tor body (112).

4) The nut (126) is loosened using thin pliers or a


small open end wrench.

5) The inlet nipple is reinstalled.

Docu# 010502002 PAGE 65


SUPERLITE-17
6) The regulator is pressurized and tested. There
must be no more than 1/8 inch play in the roller
end of the lever. It may be necessary to repeat
these six steps as the method requires estimating
the correct position of the nut.

7) Replace the diaphragm (122).

8) Press the cover (123) over the diaphragm. Hold


the cover tightly against the diaphragm.

9) Press the purge button in the cover. There must


be 1/8 inch travel before the purge button touches
the diaphragm. If there is no travel, or more than
1/8 inch travel in the purge button, it may be nec-
essary to bend the lever to its proper height as
explained in Section 6.8.10. If the purge button
seems to be correct, proceed with assembly.

10) Install the clamp (125) and clamp screw (124).


Tighten the screw. See torque specifications in
Fig. 6.53 In an emergency, if you have lost the
Appendix 1.
DSI regulator tools, you can get by using a small
screwdriver and a pair of pliers.
11) Again, press on the purge button in the cover.
It must have 1/16 inch minimum and 1/8 inch
maximum free travel before it meets the dia- 1) Turn off the breathing gas (or air) supply.
phragm. If there is more than 1/8 inch travel, the
lever must be bent upward. If the button has only 2) Bleed the regulator so no pressure is present.
slight or no free travel, the lever must be bent If the lever is so loose that it cannot be used to
down. bleed the system, the next step will do so.

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

If there is no flow when the regulator is pressur-


ized, and the lever (128) is very loose (travels
more than 1/8 inch at the roller end), the nut (126)
must be tightened.

PAGE 66 Docu# 010502002


SUPERLITE-17
7) Back out the adjustment knob a few turns until
a slight steady flow starts, then in until it just stops. 6.8.14 UNEXPLAINED DEMAND
REGULATOR STEADY FLOW
8) Tighten the nut (126) until the loose lever has WHEN UNDERWATER
about 1/8 inch play at the roller end. The adjust-
ment wrench is the best tool for this. Any leak in the neck dam when the diver is face
down will cause gas to vent out into the water
9) Replace the diaphragm (122). from the inside of the helmet. This causes the
demand regulator to steady flow, making up for
10) Press the cover (123) over the diaphragm. the vented gas. Even if the adjustment knob is
Hold the cover tightly against the diaphragm. turned in, the leak may continue.

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.

12) Install the clamp (125) and clamp screw (124).


Tighten the screw.

13) Again, press on the purge button in the cover.


It must have 1/16 inch minimum and 1/8 inch
maximum free travel before pushing the dia-
phragm in contact with the lever causing the start
of gas flow. 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.

14) If the purge button travel is correct, the ad-


justment is complete.

Docu# 010502002 PAGE 67


SUPERLITE-17
6.9 ORAL/NASAL 6.9.2 INSPECTION OF ORAL/NASAL
6.9.1 ORAL/NASAL REMOVAL
1) Inspect the oral/nasal mask. If it is torn or aged
Tools Required: it must be replaced.
7/16 inch Open End Wrench
2) Inspect the oral/nasal valve (84). If it is torn
The oral/nasal mask is easily replaced. or aged it must be replaced.

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.

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SUPERLITE-17
6.10 WHISKER EXHAUST
6.10.1 WHISKER REMOVAL

Tools Required:
1/4 inch Flat Blade Attachment on Torque Screw-
driver

1)The rubber whisker (139) is removed by stretch-


ing and pulling the rubber away from the back of
the regulator (112). A metal cup called the ex-
haust flange surrounds the regulator rubber ex-
haust valve. The whisker is held in place at the
Fig. 6.56 Oral nasal mask with equalizing device, regulator body by being stretched over the ex-
exhaust valve, and mount nut. haust flange.

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.

3) Reinstall the nose block device (86).

o-ring
port

whisker

Fig. 6.57 Attachment of the whisker exhaust to the port.


Docu# 010502002 PAGE 69
SUPERLITE-17
3) Before removing the regulator exhaust valve, 6.11 MAIN EXHAUST ASSEMBLY
carefully inspect the area around the edges to as-
sure the rubber exhaust valve is in contact with The main exhaust assembly (149-152) is held in
the regulator body. The metal cross area of the place by the three screws (148) that are installed
body under the valve could be slightly bent out from the inside the helmet shell. RTV silicone
resulting in the rubber valve (137) not sealing. If sealant is used to seal the main exhaust body (149)
the exhaust valve is high and not sealing, lightly to the helmet shell (92).
press in on the metal cross. The exhaust valve
can remain in place during this. Bend the metal 6.11.1 MAIN EXHAUST VALVE REMOVAL
in slightly until the rubber valve seats.
Tools Required:
4) The rubber exhaust valve is removed by pull- Flat blade screwdriver
ing it out.
1) The main exhaust cover (152) can be removed
6.10.2 WHISKER REPLACEMENT by removing the two screws (151) on either side
of it.
1) Replace the regulator exhaust valve.
2) The main exhaust valve (150) must be replaced
2) Stretch the whisker onto the exhaust flange of at the slightest sign of deterioration or aging of
the regulator (112). the rubber. Simply grasp the valve and pull to re-
move.
3) Attach the screws (111), spacers (109) and plate
(111), on each side of the port retainer and torque
(see Appendix 1).

DANGER: Always be sure to use a


torque screwdriver to check the tension
of the port retainer screws. Overtighten-
ing can cause damage to the threaded
inserts in the fiberglass shell and cause
them to loosen. Without the correct ten-
sion the port retainer may come loose and
the helmet could flood. This could lead
to drowning.

Fig. 6.58 The main exhaust cover is held in


position by two screws.

PAGE 70 Docu# 010502002


SUPERLITE-17

Fig. 6.59 With the main exhaust cover off, you


have access to the main exhaust valve.

3) The main exhaust body (149) must be clean


with no sand or other debris.

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).

2) Position the main exhaust body on the helmet


shell (92) and install the screws (148). Tighten
the screws to 12 inch pounds of torque. Wipe off
any excess sealant.

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SUPERLITE-17

Fig. 6.61 Three screws hold the main exhaust body


in position.
Fig. 6.63 This is the proper orientation for the
main exhaust body. Notice the opening in the side
of the body is positioned closest to the bottom of
the helmet.

3) When the sealant has cured, per the directions


on the sealant tube, install the new valve (150).

Fig. 6.62 Silicone sealant is used to make the


seal between the helmet shell and the main
exhaust body.
PAGE 72 Docu# 010502002
SUPERLITE-17

CHAPTER 7.0
CORRECTIVE MAINTENANCE

7.1 GENERAL 7.2 HELMET SHELL (92)


This section covers the maintenance and The helmet shell (92) is constructed by hand of
repair of all non-breathing system compo- fiberglass cloth, fiberglass mat, and fiberglass
nents of the SuperLite-17 diver’s helmet. strands impregnated with polyester resin. It is
Correct repairs will result in better commu- strong, extremely durable, and not subject to
nications and improved overall diver com- stress cracking or age cracking. Many Kirby
fort and performance in getting the job done. Morgan fiberglass helmets and masks still in
Numbers appearing in parentheses below use today are more than 20 years old.
are “location” numbers that are used in the
blow-apart drawing at the rear of this manual. A polyester color coat covers the exterior of the
unit. Although this color is far more durable
WARNING: Use only Diving Sys- than paint, it can be scratched and chipped.
tems International original replacement Light scratches can be removed by using an
spares when repairing your helmet. The automotive rubbing compound and waxing.
use of other manufacturer’s parts will
interfere with the performance character- DANGER: Do not attempt to install
istics of your life support equipment and new thread inserts in the helmet shell for
may jeopardize your safety. Additionally, the port retainer screws by yourself. If the
any substitutions will void all warranties installation is done improperly, the port
offered by DSI. retainer can come loose and the helmet
could flood. This could lead to drowning.
All the spare parts in our catalog were spe- Return the helmet to Diving Systems
cifically manufactured for Kirby Morgan International for inspection and repair of
designed helmets and masks. When ordering the threaded inserts.
spares, insist on DSI original parts.

DANGER: All parts on the


SuperLite-17 must be adjusted to their
proper torque specifications. See Appen-
dix 1 for a complete listing of torque
specifications for each part. Failure to
adjust parts to the recommended specifi-
cations could lead to helmet failure and
accidents. This could be fatal.

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SUPERLITE-17
7.3 NOSE BLOCK ASSEMBLY 7.3.2 Nose Block Device Replacement
1) Prior to reassembly, lubricate the two O-
7.3.1 Nose Block Assembly Removal rings (106) with silicone grease.
Tools Required:
Slip Joint Pliers 2) Slide the shaft (86) through the helmet shell
Rag or cloth (92).
7/16 inch Open End Wrench
3) Place both o-rings (106) on the shaft (86),
1) Hold the nose block knob (108) with a pair of followed by the packing nut (107) and the knob
pliers (padded by a cloth) while unscrewing the (108).
nose block device (86) with your hand.
4) Tighten the packing nut (107) until snug. Do
2) After the knob (108) is removed, loosen and not overtighten as this will make it difficult to
remove the packing nut (107). slide the noseblock device in and out.

Fig. 7.1 Use padded pliers to remove the nose Fig. 7.2 Reinstall the knob and tighten it
block knob. securely.

3) Slip the two o-rings (106) off the end of the


shaft of the nose block device (86).
5) Tighten the knob (108) with the pliers while
holding the shaft (86) with your hand.
4) The pad end of the shaft may be bent with
pliers to better fit an individual. A larger pad of
rubber can also be glued onto this pad.

PAGE 74 Docu# 010502002


SUPERLITE-17

7.4 HANDLE AND WEIGHTS

7.4.1 Handle Removal


Tools Required:
Flat blade screwdriver

The handle is a convenient location to mount


television cameras, lights, and other instru-
ments. If the handle is to be drilled to accept any
of these items, it must be removed to prevent
accidental damage to the helmet shell.

1) The handle is removed by unscrewing the top


three port retainer screws (94).

2) Remove the rear handle mount screw (90)


and washer (91).

Fig. 7.4 Unscrew the interior handle screw.

7.4.2 Handle Replacement

1) Clean off all the old RTV (silicone sealant)


remaining on the handle (93) and the helmet
shell (92).

2) Place a liberal amount of RTV on the rear


mount surface of the handle and in the mount
screw hole in the helmet shell (92).

DANGER: Do not breathe the fumes


from uncured silicone sealant. These
fumes are dangerous and can cause un-
consciousness. They can also cause long
term damage to body tissue. Read and
Fig. 7.3 Release the top three screws that hold the follow all precautions listed on the sili-
handle in position. cone sealant tube.

3) Pry up the handle (93) to break loose the


RTV.

Docu# 010502002 PAGE 75


SUPERLITE-17
3) Position the handle (93) and run in the front
screws (94) until snug.

4) Hold the handle in place and thread the rear


mount screw (90) with its washer (91). Adjust
this screw until it is snug, not tight.

5) Tighten the front mount screws (94) to their


proper torque value.

6) Tighten the rear mount screw to its proper


torque value.

7) Wipe off any excess RTV from the helmet


shell.

7.4.3 Weight Removal


Tools Required:
Flat blade screwdriver
Wooden wedges

The weights are held on by fasteners and sealed


with RTV. Before removing the weights (75,89, Fig. 7.6 You will need a wooden wedge to break
95) take note of the position of the snap tabs the seal between the weight and the helmet shell.

(78) and earphone retainer clips (147). If the


snap tabs are not installed correctly, it will be
difficult to reinstall your head cushion.

1) Unscrew the snap tab screws (79) and ear-


phone retainer screws (76).

2) Insert wooden wedges under the edges of the


weights.

CAUTION: Do not use a screwdriver


or similar sharp instrument as it will
damage the fiberglass finish.

3) On the port and starboard weights (75, 95)


this is best done starting along the bottom edge.

4) On the rear weight (89), start removal at the


corners.

Fig. 7.5 To release the weights, the interior screws


must be removed.
PAGE 76
Docu# 010502002
SUPERLITE-17
4) Surround the holes with RTV (silicone seal-
ant) to seal all penetrating screws. Be liberal
with the RTV as it must seal the weights to
prevent water entry.

DANGER: 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
Fig. 7.7 Separate the weight from the helmet shell. on the silicone sealant tube.
5) Be patient and take your time because the
5) Install the screws (76, 79, 90) and washers
RTV is an excellent adhesive and makes re-
(77) and tighten to the required torque values.
moval of the weights difficult. If you are hasty
Make sure all snap tabs and earphone retainer
you may damage the helmet shell.
clips are in their original positions.
7.4.4 Weight Replacement
6) Wipe off all excess RTV that has oozed out
from under the weights.
1) Clean off all traces of the old RTV.
7) Allow 24 hours for the sealant to cure before
2) If the original weights are reinstalled they
using the helmet.
will fit the shape of the helmet and hole posi-
tion. Replacement weights may need to be ad-
justed and aligned.
7.5 ALIGNMENT SLEEVE
The alignment sleeve (88) provides the attach-
3) Check the fit of the replacement weights. If ment point for the rear hinge tab (26). It should
the holes in the shell do not line up with the never need replacing, unless it is bent or other-
holes in the weights the holes may be enlarged wise seriously damaged.
with a round file. Do not make the holes too big.
Extend them only as necessary to fit the screws. 7.5.1 Sleeve Removal
If the holes are too big there will be insufficient Tools required:
material to keep the snap tabs (78) in place. Flat blade screwdriver

1) To remove the sleeve, simply unscrew it


from its attachment to the rear weight (89). The
sleeve slips over the screw (87) that holds it in
place.

7.5.2 SLEEVE REPLACMENT

1) Apply Loctite® to the screw and screw it into


the rear weight until the screw just bottoms out.

Fig. 7.8 Apply silicone sealant to the weight


before installing it on the helmet.

Docu# 010502002 PAGE 77


SUPERLITE-17
7.6 PORT RETAINER
The port retainer (141) is made of chrome
plated brass. We exercise extreme care in
installing the nose block guide, located in
the lower center front.It is fastened in place
using 626 Loctite ®. Under normal use, the
port retainer should never need replacement.

7.7 FACE PORT

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.

7.7.2 FACE PORT AND NOSE BLOCK DEVICE


Fig. 7.9 Removing the nut from the nose block
REMOVAL
device.
Tools Required:
7/16 inch Open End Wrench
1/4 inch Flat Blade Attachment on Torque
Screwdriver
Slip Joint Pliers

1) First remove the nose block device knob


(85) then the packing nut (84).

2) Slip the o-rings (82) off the nose block


shaft (51) and pull the nose block device out
through the interior of the oral/nasal mask
(50).

3) Remove the handle (59) as per Section


6.7.1.

4) Next, unscrew the remaining twelve port


retainer screws (80, 89). Pull the retainer
(78) clear of the helmet shell (58).

5) Be sure not to lose the O-ring (81) that is


located on the back side of the port retainer
at the nose block device packing. Fig. 7.10 Removing the nose block device from
inside the helmet.
PAGE 78 Docu# 010502002
SUPERLITE-17
6) The four whisker spacers (87) must not be
misplaced. They will usually be found lodged
in the whisker (86).

7) Remove the old port (77) and sealing O-


ring (76).

7.7.3 FACE PORT AND NOSE BLOCK REPLACEMENT

1) Clean the O-ring groove that is in the


helmet shell (58).

2) Coat the O-ring (76) with DC111 lubri-


cant and replace in the helmet shell (58).

WARNING: The O-ring on the face


port of the SuperLite-17A/B is made from
a special compound and has unique di-
mensions. It is a softer durometer O-ring
than is commonly available. There are no
equivalent o-rings manufactured by other
Fig. 7.11 Removing the port retainer screws. vendors. This O-ring must be replaced
with a D.S.I. O-ring. Failure to do so could
lead to seal failure.

3) Place the new face port (77) into the


helmet shell (58) making sure the O-ring
(76) is in its proper groove.

4) Clean and lubricate the small O-ring (81).

5) Slip the O-ring (81) on the small tube that


protrudes from the rear of the port retainer
(78). Place the entire port retainer onto the
helmet shell (58), holding it in place against
the port (77) and face port O-ring (76)
while the twelve screws ( 80, 89) are all run
in loose. Replace the handle (59) as per
Section 6.7.2.

6) Slightly tighten each screw, one after


another, until they are all snug (12 inch
pounds of torque) and the O-ring (76) has
completely sealed the face port (77).

Fig. 7.12 Don't misplace the whisker spacers.

Docu# 010502002 PAGE 79


SUPERLITE-17
DANGER: Always be sure to use a
torque screwdriver to check the tension
of the port retainer screws. Overtighten-
ing can cause damage to the threaded
inserts in the fiberglass shell and cause
them to loosen. Without the correct ten-
sion the port retainer may come loose
and the helmet could flood. This could
lead to drowning.

NOTE: Testing of the inserts should be done at


least ONCE A YEAR with DSI Part #525-115
Thread Insert Testing Block Kit.

When testing the Thread Inserts on a helmet, or


when removing and replacing the port retainer, it
is crucial that the DSI recommended torque
specs be followed when tightening the Port Re-
tainer Screws. Any over torquing of a screw can
result in serious damage to either the thread insert
or the surrounding fiberglass in the port area.
This can lead to loosening of the Port Retainer
Fig. 7.13 Remove the face port to clean the O-ring
groove.

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.

DANGER: Never use a third party


face port. Its thickness or diameter may
be incorrect and cause the helmet to flood.
It could also be made of inferior materials
causing it to fail. This could be fatal.

Docu# 010502002 PAGE 81


SUPERLITE-17
7.8 COMMUNICATIONS SYSTEM 2) Check the wire connections. They must be
solid.
7.8.1 General
The communications system in the SuperLite- 3) Check the mylar diaphragm. If the mylar is
17 A/B requires regular attention and mainte- torn, or loose, replace the entire unit. Although
nance for proper function. Clear two way speech cardboard speakers are available at a lower
communications between the diver and his sur- initial cost than our mylar speakers, they are a
face crew is one of the most important capabili- poor investment. Cardboard speakers must be
ties of surface supplied diving operations. replaced almost five times as often as our mylar
speakers. Cardboard speakers should only be
7.8.2 Earphone Inspection used in emergency situations.

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.

1) Remove the nuts (145) and washers (146)


from the communications posts (154). If you
are using the optional terminal block (153) this
may be where the wires from the earphone and
microphone are connected.

2) Lift the terminal lugs off of the communica-


tions posts. Note the position of the terminal
wires.

3) Slowly pull the microphone (73) out of the


oral nasal mask (83). The wires that connect it
to the communications posts (154) will follow.

4) Install the terminals for the new microphone.


Note that the wires must go on separate termi-
nals as before.
Fig. 7.16 The earphones must be inspected on a
regular basis. Replace them when they show signs 5) Tighten the nuts (145) carefully, without
of corrosion or any time communications are not turning the communications posts. If the posts
clear. turn, it means that the seal made by the silicone
sealant on the helmet shell has been broken. If
PAGE 82 Docu# 010502002
SUPERLITE-17
1) Remove the nuts (145) and washers (146)
from the communications posts (154). If you
are using the optional terminal block (153) this
may be where the wires from the earphone and
microphone are connected.

2) Lift the terminal lugs off of the communica-


tions posts. Note the position of the terminal
wires. Discard the old earphones.

4) Install the terminals for the new earphones


(71, 72). Note that the wires must go on sepa-
rate terminals as before.

5) Tighten the nuts (145) carefully, without


turning the communications posts (154). If the
posts turn, it means that the seal made by the
silicone sealant on the helmet shell has been
broken. If this happens the posts (154) will
allow water to leak into the helmet.

CAUTION: Take care not to break


the seal made by the silicone sealant where
Fig. 7.17 You can replace all the communications the communications posts penetrate the
components at once, or individually, as necessary. helmet shell. If these posts turn, the hel-
this happens the posts (154) will allow water to met will leak. This could lead to a rapid use
leak into the helmet. of the breathing gas as the diver attempts
to keep the helmet clear.
CAUTION: Take care not to break
the seal made by the silicone sealant where
the communications posts penetrate the
helmet shell. If these posts turn, the hel-
met will leak. This could lead to a rapid use
of the breathing gas as the diver attempts
to keep the helmet clear.

7.8.4 Earphone Removal and Replacement


Tools Required:
1/8 inch flat Blade Screwdriver

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.

Docu# 010502002 PAGE 83


SUPERLITE-17
7.8.5 Waterproof Connector
SuperLite-17 helmets are supplied either with
an optional waterproof connector (158) or a set
of terminal posts. The optional waterproof con-
nector is subject to failure if the helmet re-
ceives rough handling. To replace the connec-
tor use the following procedure.

Fig. 7.19 Waterproof connectors help improve


communications.

7.8.5.1 Connector Removal


Tools Required:
3/8 inch Open End Wrench
5/8 inch Open End Wrench Fig. 7.20 To remove the waterproof connector,
11/16 inch Open End Wrench you must remove the plastic nut inside the helmet.
3/4 inch Open End Wrench

1) Remove the earphone wire lugs from the


interior of the communications posts (154) or
terminal block.

2) Remove the nut (144) from the packing


gland (159) on the interior of the helmet shell
(92).

3) Separate the connector/packing gland as-


sembly (157, 158, 159, 160, 161, 162, 163)
from the helmet shell (92).

4) Place the packing gland (160) in a vice and


unscrew the packing nut (163).

5) Pull the connector (158) through the gland


(160). (Note: It will be much easier to do this if
the lugs are cut off the end of the connector
first. Save the front and back ferrules (161,162) Fig. 7.21 Separating the waterproof connector
and the packing nut (163). from the helmet.
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SUPERLITE-17
7.8.5.2 Connector Replacement
1) Lubricate the new connector (158) with sili-
cone grease.

2) Slide the packing nut (163) and ferrules


(161,162) onto the new connector.

3) Feed the connector through the packing


gland (160).

4) Check the O-ring (159) on the packing gland.


Replace or lubricate as necessary.

5) Install the connector/packing gland assem-


bly (164) in the helmet shell (92).

6) Tighten the nut (144) on the packing gland


until it is snug.

77) Connect the wire lugs on the connector to


the communications posts (154) or terminal
block (153) as preferred.

7.8.6 Communications Posts

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).

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SUPERLITE-17
7.9 NECK CLAMP/YOKE ASSEMBLY

7.9.1 Yoke

7.9.1.1 Yoke Removal and Disassembly


Tools Required:
Flat blade screwdriver

The yoke should be separated from the neck


clamp if you plan to have it refinished. Refin-
ishing must only be performed by a DSI autho-
rized facility.

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.

2) Remove the three screws (29) and washers


(30) that secure the hinge (23) to the yoke.

Fig. 7.22 Remove the three rear hinge screws.

7.9.1.2 Yoke Replacement and


Reassembly

1) Insert the three screws (15) through the yoke


(31) and thread them into the latch catch assem- Fig. 7.24 Tighten the screws that connect the latch
bly (22). Tighten with the screwdriver to 20 catch to the yoke.
inch pounds of torque.

2) Install the three screws (29) and washers (30)


at the rear of the yoke and into the hinge (23).
Tighten to 20 inch pounds of torque.

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7.9.2 Latch Catch Assembly

7.9.2.1 Latch Catch Mechanism


Disassembly
Tools Required:
Block of wood
Pin punch
Ballpeen hammer

With the latch catch assembly (22) positioned


on the edge of a block of wood, use the follow-
ing procedure.
Fig. 7.26 Keep the shaft from turning by using the
1) Drive the pin (16) through the knob. safety pin when you unscrew the knob.

2) Unscrew the knob, which has been fastened


with Loctite®. Use the safety pin to prevent the
shaft from turning while you unscrew the knob.

Fig. 7.27 Remove the knob from the latch catch


mechanism.

Fig. 7.28 Remove the shaft and spring.

Fig. 7.25 Drive the pin through the latch catch


body. 3) Remove the safety pin and remove the shaft
and spring.

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SUPERLITE-17
4) Clean all parts in a mild solution of white 7.9.3 Neck Clamp Assembly
vinegar and water.
7.9.3.1 Neck Clamp Assembly
5) Remove all traces of Loctite® from the shaft. Adjustment
Tools Required:
7.9.2.2 Latch Catch Mechanism 7/16 inch open end wrench
Reassembly
The neck clamp assembly (7) will periodically
1) Slide the spring (20) onto the shaft. need adjustment as the neck dam ages and
grows thinner. Replacement of the neck dam
2) Insert the shaft (21) into the latch catch body. will also require neck clamp adjustment.

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.

2) The outer nut (6) has a nylon insert. This nut


should periodically be replaced when it is no
longer tight on the neck clamp stud.

3) When the neck clamp assembly is correctly


adjusted, the clamp should fit tight at the middle
of its travel when mated to the helmet shell
(92). Once the lever is past the mid-line, move-
ment of the lever should be easy. From the
closed position, the diver should be able to pull
Fig. 7.29 Removing the spring from the latch the lever open about an inch and when released
catch body. the lever should snap closed.
end of the shaft.
4) Proper adjustment of the neck clamp (7)
5) Drive the pin through the hole in the knob places the bail of the neck clamp squarely in the
and the shaft until the end of the pin is flush groove of the latch catch body (19) when the
with the side of the knob. clamp is closed.

5) If the neck clamp binds and does not close


correctly after adjustment, the neck clamp must
be straightened. To help ensure the proper ac-
tion of the clamp, this must be done by the DSI
factory or an authorized service center.

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SUPERLITE-17
tween the front seam and the large reinforcing
DANGER: The neck clamp must close
patch. Feed the stud and handle through the
properly for the helmet to stay on the diver
hole from the same side the patch is located on
correctly. If the neck clamp does not func-
to the opposite side of the neck dam.
tion properly the helmet could come off
the diver’s head. Drowning could result.
4) Position the neck dam so that it doesn’t slide
any further onto the neck clamp assembly (7).
Slide the open end of the neck clamp assembly
onto the opposite side of the clamp, engaging
the tracks of the clamp. Hold the neck dam (2)
and the neck clamp assembly so the clamp does
not come apart.

5) Feed the small hole in the neck dam over the


adjustment block on the neck clamp assembly.

6) Place the lock washer (5) on the adjustment


stud on the neck clamp (7).
Fig. 7.29 Neck clamp adjustment is controlled by
the amount of the stud that protrudes from the 7) Insert the adjustment stud through the adjust-
block on the neck clamp ring. ment block on the neck clamp assembly (7).
Thread the lock nut (6) onto the adjustment
7.9.4 Neck Dam

7.9.4.1 Neck Dam Removal

Worn neck dams may simply be cut off the neck


clamp for fastest replacement.

7.9.4.2 Neck Dam Replacement

Tools Required:
7/16 inch wrench

1) Remove the old neck dam (2). Remove the


nylon lock nut (6) from the adjustment stud on
the neck clamp assembly. Place the lock nut and
washer (5) aside so they are not lost.

2) Place the yoke/neck clamp assembly in your


lap, or on a table, upside down. Swing the yoke
(31) up until it is against your chest. Hold the
neck clamp (7) handle and the adjustment stud
together in your right hand.
Fig. 7.30 Swing the yoke up against your chest.
3) Do this step very carefully. Locate the large
The yoke/neck clamp assembly is upside down
hole in the neck dam (2), which is found be-
here.
PAGE 89
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SUPERLITE-17

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.

stud. (Replace the lock nut if the nylon insert is


worn.) Do not tighten at this time.

8) Feed the tab at the rear of the neck dam (2)


through the space between the sleeve (24) and
the rear hinge tab (26). Pull the tab up as far as
it will go. NOTE: You may find it easier to pull
the tab through this space by tying a separate
loop of string through the tab and feeding it
through first.
Fig. 7.32 Feed the stud and handle through the
hole.
9) Feed one end of the string through the tab in
the neck dam. Draw up on the string until the
neck dam material is snug. Do not overtighten.
Tie a series of square knots (at least three) with
the string. Tape the knots with electrical tape.
Tuck the knots into the sleeve of the neck dam.
Adjust the neck dam as per section 6.17.3.3.

Fig. 7.33 Feed the small hole in the neck dam over
the adjustment block.

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SUPERLITE-17
7.10 O-RING SEAL REPLACEMENT
The O-ring seal (80) on the base of the helmet
shell (92) should be replaced on an annual
basis, or whenever it shows signs of wear. The
O-ring seal makes the seal between the helmet
shell and the yoke/neck clamp/neck dam as-
sembly (2-30). To replace the O-ring (80) sim-
ply stretch it over the bottom of the helmet shell
The O-ring seal should be periodically lubri-
cated with a light coat of silicone grease.

Fig. 7.35 Pull the tab through the space between


the sleeve and the rear hinge tab.

Fig. 7.37 Replace the O-ring on the base of the


helmet whenever it is worn.

Fig. 7.36 Tie several knots in the drawstring and


tuck it back inside the edge of the neck dam.
7.11 HEAD CUSHION FOAM
REPLACEMENT
The head cushion (1) foam should be replaced
when the foam begins to crumble. Order re-
placement kit, DSI Part #510-523. A loose head
cushion will create a sloppy fit and cause dis-
comfort for the diver.

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NOTES

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SUPERLITE-17

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.

8.2 HOT WATER SHROUD INSTALLATION


PROCEDURES
The Hot Water Shroud (DSI Part #525-100)
should be used whenever diving operations
are conducted on mixed gas, or in cold
water. The procedures for the installation of
the hot water shroud are as outlined below:

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

1) Disconnect the bent tube assembly (45b)


at the side block end only. Loosen the jam
nut (131b) at the regulator. If the bent tube
will not swivel freely, you must loosen the
large nut at the regulator.

2) Remove the free flow knob (34), locknut


Fig. 8.1 Pull the hot water shroud over the
(32), and spring (33).
regulator.
3) Remove the emergency valve knob (55),
nut (57), and spring (56). 6) Install the rubber side block cover. Start
by inserting the non-return valve (68) through
4) Screw the regulator adjustment knob (120) the square hole on the back side of the cover.
in all the way. All the other holes will then line up cor-
rectly.

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SUPERLITE-17
7) Slide one of the PVC flanges (DSI Part
#520-046) over the bent tube (45b).

8) Install the second PVC flange in one end


of the corrugated tube, (1/4 of the flange
should still show).

9) Compress the corrugated tube and slide it


over the bent tube. The PVC flange previ-
ously installed in the corrugated tube mates
with the side block cover.

10) Attach the side block end of the bent tube


to the side block assembly (43b). Tighten
with an 11/16 inch wrench.

11) Retighten jam nut (131b). You will need


to slide the PVC flange towards the side
block.

12) Stretch the corrugated tube over the side


block and regulator covers.
Fig. 8.2 Install the shroud over the sideblock.

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.

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SUPERLITE-17

Fig. 8.7 Completed installation of the hot water


shroud.

13) Attach the tie wraps over the corrugated


Fig. 8.5 The second PVC tube is installed at the tube at the PVC stiffeners and tighten.
sideblock.
14) Trim the excess ends from the tie wraps.

15) Reinstall the free flow knob (34), spring


(33), and lock nut (32).

16) Reinstall the emergency valve knob (55),


spring (56), and nut (57).

17) The completed installation should ap-


pear as pictured above.

Fig. 8.6 Use a cable tie gun to tighten the cable


ties to the proper tightness.

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SUPERLITE-17
8.3 LOW PRESSURE INFLATOR HOSE
INSTALLATION ON THE B SIDEBLOCK
The low pressure inflator system may be
used with either conventional buoyancy com-
pensators or dry suit systems. For certain
pieces of equipment it may be necessary to
use a longer inflator hose than is originally
supplied by the manufacturer of the low pres-
sure system.

Tools Required:
5/32 inch Allen Wrench Attachment on
Torque Wrench

1) Remove the plug (48) from the side block.


Save this plug
.
2) Check the o-ring on the low pressure whip
to be sure it is present and in good condition.
Carefully screw the low pressure whip into
the side block. Fig. 8.9 Don’t misplace the plug.

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.

4) Pressurize helmet and test connection for


leaks.

CAUTION! When using the low pres-


sure port on the side block for attachment
of a low pressure hose, a hose with built
in flow restriction or the DSI Flow
Restrictor Adapter, DSI P/N 555-210 must
be used.

8.4 WELD LENS/WELD SHIELD ASSEMBLIES


Fig. 8.11 Remove the plug screws from the port
Tools Required:
retainer.
3/8 inch Open End Wrench
1/4 inch Flat Blade Attachment on Torque
Screwdriver

1) Remove the two plug screws (103) from


the port retainer (141). Refer to the drawing
included with the weld lens or weld shield
assembly kit for the remainder of the loca-
tion numbers.

2) Insert the screws through the spacer wash-


ers and then through the mount ears.
Fig. 8.12 Install the screws in the mount ears.
3) With the rubber bumpers facing the inside
of the helmet(weld lens assembly), install
and tighten the two mount bolts into the port
retainer.

DANGER: Use only the bolts pro-


vided with the kits for installation of these
assemblies. Longer bolts will damage the
helmet shell and/or the threaded inserts.
This could cause flooding through the
port.

4) Tighten the two lock nuts on the ends of


the hinge studs so that the welding lens as-
sembly can be flipped up, but will not fall
down from its own weight. The Weld Shield
assembly comes pretightened from the fac-
tory and should not need any adjustment.

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SUPERLITE-17
8.6 USE OF QUICK DISCONNECT
A quick disconnect should be used with all
bail-out systems. It provides greater conve-
nience on deck while dressing the diver. It
also makes it possible to separate the attach-
ment of the bail-out from the helmet should
the diver become entangled underwater.

A quick disconnect is designed to be in-


stalled in any low pressure port of the diver’s
bail-out regulator. The connector splits the
hose into two halves, with a male connector
on one end and a female connector on the
other. The female connector should be
equipped with a sleeve lock that must be
properly aligned before the hose can be dis-
engaged.

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!

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SUPERLITE-17
8.7 DOUBLE EXHAUST INSTALLATION 2) Remove the main exhaust body (149) and
The double exhaust system helps prevent a clean off all traces of the old silicone sealant.
backflow of biological and certain chemical con-
taminants into the helmet. This system has been 3) Following the instructions in Section 6.7.5,
used successfully for diving in biologically con- remove the regulator and exhaust whisker.
taminated environments. However, there are cer- This will require removal of the nose block
tain chemicals (i.e.. Toluene, Acetic acid etc.) that device, oral nasal and bent tube.
will attack the rubber in the valves in the exhaust
assembly . 4) Attach the double exhaust whisker to the
regulator exhaust flange. Secure with a tie
BE AWARE OF WHAT YOU ARE DIVING wrap, DSI Part #520-039.
IN! More information on contaminated diving
and high-risk chemicals may be found in the
publication "Diving in High-Risk Environments"
by Steven Barsky.

DANGER: Diving in contaminated


water is extremely hazardous. Do not dive
unless you know exactly what contami-
nants are in the water and you are certain
they are compatible with all parts of your
diving system.

Tools Required: Fig. 8.16 Attach the double exhaust whisker to


1/4 inch Flat Blade Attachment on Torque the regulator
Screwdriver

1) Remove the two whisker kidney plates


and spacers and screws. These will be used
in the installation/reassembly.

Fig. 8.17 Secure the double exhaust whisker to


the regulator using the tie wrap.

5) Install the double exhaust body using sili-


cone sealant to seal it to the helmet and the
three screws (148) that held the main ex-
haust body in position.
Fig. 8.15 The double exhaust kit.
6) Install the regulator in the helmet, with the
regulator mount nut hand tight.
Docu# 010502002 PAGE 99
SUPERLITE-17
7) Attach the double exhaust whisker to the
main exhaust body. Make sure the internal
rubber ridge is in the groove in the main
exhaust body. Secure it with a tie wrap, DSI
Part #520-042.

8) Attach the bent tube.

9) Secure the whisker with the screws, spac-


ers and kidney plate removed earlier.

10) Tighten the regulator mount nut and bent


tube attachments.

11) Reinstall the oral/nasal and nose block


device.

DANGER! Any helmet/dry suit sys-


tem must be leak tested according to the
manufacturer's instructions before EV-
ERY dive in contaminated water!
Fig. 8.18 Apply silicone sealant to the double
exhaust body.

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

Fig. 8.23 The double exhaust kit appears like this


when properly installed on the SuperLite-17.

12) Allow 24 hours for the silicone sealant to cure


Fig. 8.21 Slide the double exhaust whisker tube before diving with the helmet. Test the helmet
over the double exhaust body. for leakage before diving in contaminated water.

DANGER: The exhaust valves used


in the double exhaust system and regula-
tor must be regularly inspected and re-
placed whenever they show the slightest
signs of wear. If this is not done, leakage
into the helmet and breathing system may
occur. This can be fatal, depending on the
type of contaminant the to which the diver
is exposed.

Fig. 8.22 Firmly attach the whisker tube to the


double exhaust body using a tie wrap.
Docu# 010502002 PAGE 101
SUPERLITE-17

NOTES

PAGE 102 Docu# 010502002


SUPERLITE-17

APPENDIX I
TORQUE SPECIFICATIONS FOR SUPERLITE-17A/B

Location DSI Part Torque in


Description
Number # Inch Pounds
36 550-020 Bonnet, Defogger Valve 100
42 550-024 Stud, Side Block 50
45b 555-154 Bent tube assy. side block end 100
48 550-094 Low pressure plug 50
50 550-140 Emergency valve body 3 turns by hand
54 550-032 Packing nut, emergency valve 45 after seating
60 One way valve body 240
66 One way valve seat 240
67 555-117 Adapter, brass 3 turns by hand
68 555-195 One way valve 240
82 550-081 Regulator mount nut 100
76, 90 530-070 Screw, for mounting weights 30
94 530-045 Screw, handle 12
101 530-317 Nut, air train 20
98 530-317 Nut, air train 20
102 530-050 Screw, sideblock 18
148 530-035 Screw, main exhaust body 12
108 550-062 Knob, nose block 23
104 530-035 Screw, port retainer 12
103 530-052 Screw, port plug 18
119 550-055 Packing nut, regulator 40 after seating
124 530-030 Screw, regulator clamp 8
132b 550-048 Inlet nipple, regulator B 40
130a 550-046 Inlet nipple, regulator A 40
131b 550-050 Jam nut, regulator 100
111 530-045 Screw, whisker kidney plate 12
25 530-201 Bolt, rear hinge tab 70
29 530-080 Screw, yoke 20
15 530-066 Screw, yoke 20

Docu# 010502002 PAGE 103


SUPERLITE-17 Table of Equivalents

To convert units appearing in TO CONVERT INTO MULTIPLY BY


Column 1 (left column) into INTO TO CONVERT DIVIDE BY
equivalent values in Column
2 (center column), multiply Atmospheres Feet of Water 33.9
Atmospheres Inches of Mercury (Hg) 29.92
by factor in Column 3. Ex- Atmospheres PSI (LBS per Sq. Inch 14.7
ample: To convert 7 gallons BTU Foot Pounds 778.3
into cubic inches, multiply 7 BTU per hour Watts 0.2931
x 231 = 1617. To convert BTU per minute HorsePower 0.02356
o
Celsius (Centigrade) Fahrenheit C x 1.8 + 32
units appearing in Column 2 Centimeters Inches 0.3937
(center) into equivalent val- Cubic Centimeters Gallons (U.S. Liquid) 0.0002642
ues of units in Column 1 (left), Cubic Centimeters Liters 0.0001
Cubic Feet Cubic Inches 1728
divide by factor in Column Gallons (U.S. Liquid)
Cubic Feet 7.48052
3. Example: To convert 25 Cubic Inches Cubic Feet 0.0005787
horsepower into Btu per Cubic Inches Gallons (U.S. Liquid) 0.004329
minute, divide 25 by 0.02356 Days Seconds 86.400
Degrees (Angle) Radians 0.01745
= 1061 Meters 0.3048
Feet
Feet Miles 0.0001894
Feet of Water Atmospheres 0.0295
Feet of Water Inches of Mercury (Hg) 0.8826
Feet of Water PSI (Lbs per Sq. Inch) 0.4335
Feet per Minute Miles per Hour 0.01136
Feet per Second Miles per Hour 0.6818
Foot-Pounds BTU 0.001286
Foot-Pounds per Minute Horsepower 0.0000303
Foot-Pounds per Second Horsepower 0.001818
Gallons (U.S. Liquid) Cubic Feet 0.1337
Gallons (U.S. Liquid) Cubic Inches 231
Gallons of Water Pounds of Water 8.3453
Horsepower BTU per Minute 42.44
Horsepower Foot-Pound per Minute 33,000
Horsepower Foot Pounds per Second 550
Horsepower Watts 745.7
Hours Days 0.04167
Hours Weeks 0.005952
Inches Centimeters 2.54
Inches of Mercury (Hg) Atmospheres 0.03342
Inches of Mercury (Hg) Feet of Water 1.133
Inches of Mercury (Hg) PSI (Lbs. per Sq. Inch) 0.4912
Inches of Water PSI (Lbs. per Sq. Inch) 0.03613
Liters Cubic Centimeters 1000
Liters Gallons (U.S. Liquid) 0.2642
Micron Inches 0.00004
Miles (Statute) Feet 5280
Miles per hour (MPH) Feet per Minute 88
Miles per hour Feet per Second 1.467
Ounces (Weight) Pounds 0.0625
Ounces (Liquid) Cubic Inches 1.805
Pints (Liquid) Quarts (Liquid) 0.5
Pounds Grains 7000
Pounds Grams 453.59
Pounds Ounces 16
PSI (Pounds per Sq. Inch) Atmospheres 0.06804
PSI (Pounds per Sq. Inch) Feet of Water 2.307
PSI (Pounds per Sq. Inch) Inches of Mercury (Hg) 2.036
Quarts Gallons 0.25
Square Feet Square Inches 144
Temperature (oF - 32) Temperature (oC) 0.5555
Tons (U.S.) Pounds 2000
Watts Horsepower 0.001341

PAGE104 Docu# 010502002