Operations & Maintenance Manual for the EXO Original and ... · Document # 020905002 Kirby Morgan Dive Systems, Inc. (KMDSI) is the same corporation (with only a name change) that

Operations & Maintenance Manual

for the EXO Original

and EXO Balanced Regulator Full Face Mask.

Kirby Morgan Dive Systems, Inc.425 Garden Street

Santa Barbara, CA 93101, USATelephone (805) 965-8538

FAX (805) 966-5761E-Mail: [email protected] Site:www.KirbyMorgan.com

Part #: 100-030

SuperLite-17, SuperLite-27, SuperLite-17C, SuperLite-17K, Band Mask, Kirby Morgan, DCS-2A, EXO-26

and KMB are all registered trademarks of Kirby Morgan Dive Systems, Inc. Use of these terms to describeproducts that are not manufactured by KMDSI is not permitted.

© Copyright 1987-2003 Kirby Morgan Dive Systems, Inc. All rights reserved. This manual is made availablefor the express use of owner of this Kirby Morgan product. No part of this manual may be reproduced, storedin any retrieval system, or transmitted, or used in any form or by any means, whether graphic, electronic,mechanical, photocopy, or otherwise by technology known or unknown, without the prior written permissionof Kirby Morgan Dive Systems, Inc.

Document # 020905002

ii

EXO Full Face Mask Manual

© Copyright 1970-2003 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 020905002

WARNING: Diese Mitteilung ist wichtig. Bitte übersetzen lassen.

WARNING: Ceci est important. Veuillez traduire.

WARNING: Quest è un avviso importante. Tradurlo.

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

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

Definitions of Signal Words Used in this Manual

For your protection, pay particular attention to items identified by signal words in this manual. Theseterms are identified as, CAUTION, WARNING AND DANGER. It is especially important for you toread and understand these sections.

DANGER: This word indicates an imminently hazardous situation, which if notavoided, will result in death or serious injury.

WARNING: This word indicates a potentially hazardous situation which, if notavoided, could result in death or serious injury.

CAUTION: This word indicates a potentially hazardous situation which, if notavoided, may result in minor or moderate injury. It may also be used to alert againstunsafe practices.

If English is not your native language and you have any difficulty understanding the language of anywarnings as they appear in the manual, please have them translated.

If you have any questions regarding the information in this manual, or the operation ofyour mask, call KMDSI at (805) 965-8538.

The information in this manual is intended to aid the user in optimizing the performance of this mask. This manualgives reference to using EXO- 26 masks in open circuit scuba mode as well as in surface supplied diving mode. Theuse of some of this information will often depend on the use of associated support equipment and operationalscenarios. It is not the intention of this manual to teach diving techniques, but rather to give the user the requiredtechnical information to allow Kirby Morgan helmets and masks to be integrated with the complete diving system.

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Document # 020905002 © Copyright 1970-2003 Kirby Morgan Dive Systems, Inc. All rights reserved.

DANGER: Diving is a life threatening occupation. Even if you do everything rightyou can still be killed or injured. None of the models of Kirby Morgan Band Mask canprevent accidents, injuries or death due to improper training, lack of health, impropersupervision, improper job requirements, improper maintenance or acts of God.

IMPORTANT SAFETY INFORMATION

This EXO Full Face Mask is intended for use by trained divers who have successfully completed arecognized training course in the use of a full face mask, and if used in the surface supplied mode, anapproved surface supplied diving course.

WARNING: Follow all the instructions in this manual carefully and heed all safetyprecautions. Improper use of this diving mask could result in serious injury or death.

DANGER: Kirby Morgan Dive Systems, Inc. (KMDSI) warns all divers who use theEXO Full Face Mask to use only KMDSI original spare parts from a KMDSI authorizeddealer. Although other parts, O-rings and fittings may not to be manufactured to thesame standards maintained by KMDSI. The use of any spares other than KMDSI originalparts may lead to equipment failure and accidents.

DANGER: Diving in an environment that is chemically, biologically, or radiologi-cally contaminated is extremely hazardous. Although the EXO Full Face Mask may beadapted for use in some contaminated environments, special training, equipment, andprocedures are necessary. Do not dive in a contaminated environment unless you havebeen thoroughly trained and equipped for this type of diving.

.Read this manual before using or maintaining the mask, even if you have experience with other divingmasks. If you have purchased the mask new from a dealer, be sure to send in the warranty registrationcard so we may keep you informed regarding any safety notices that affect this product. If you resell orloan this mask to another diver, be sure this manual accompanies the mask and that the person reads andunderstands the manual.

WARNING: DO NOT dive this mask in water containing high concentrations ofpetroleum based chemicals. DO NOT use any chemical locking liquids anywhere onthe mask. DO NOT use any type of aerosol sprays on the mask. These chemicals canattack, damage, and compromise the structural integrity of the plastic parts on themask . Clean the mask using only mild soap and water.

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WARNING: This mask was completely checked and should be ready to dive as itwas shipped from the factory. However, it is always the diver's responsibility to checkall the components of the mask prior to diving.

This manual is supplied to the original purchaser of this mask. If you have any questions about the useof the mask or you need another copy of this manual, Part Number 100-030, contact KMDSI. If you haveany questions regarding the use, maintenance, or operation of this mask, contact KMDSI at (805) 965-8538.

DANGER: The EXO Full Face Mask is not equipped or lubricated for oxygenservice. Using this mask with oxygen percentages above 50% by volume may lead toexplosions that can result in serious injury or death.

KMDSI regards the use of any breathing gas mixture greater than 50% 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).

All Kirby Morgan helmets, masks, and low pressure demand regulators must not be usedwith oxygen mixtures in excess of 50% oxygen by volume without first ensuring all lowpressure (less than 225 psig, 15.5 bar) gas transporting components have been cleaned foroxygen service. Only oxygen compatible lubricants such as Krytox™ and ChristoLube™should be used on components requiring lubrication and lubricants should be used spar-ingly. Never mix different types of oxygen compatible lubricants. Helmets or masks usedprimarily for air diving and occasionally for enriched gas use should be cleaned at morefrequent intervals than helmets used for mixed gas diving only.

DANGER: Kirby Morgan “High Pressure Components” (greater than 225 psig,15.5 bar) must not to be used with pure oxygen, Nitrox, or any breathing gas mix-tures with oxygen content greater than 23.5 % by volume. Using oxygen mixtures inaccess of 23.5 % by volume may lead to a fire or explosion, which could result inserious injury or death.

The Kirby Morgan SuperFlow 1st stage scuba regulator, as well as all Kirby Morgan divecontrol consoles and high-pressure gas components (greater than 225 psig, 15.5 bar) shouldnot be used with pure oxygen, Nitrox, or any breathing gas containing more than 23.5 %oxygen by volume. The first stage is not intended for use with enriched gas mixtures.

Any diving helmet, full face mask, regulator, control console or breathing life support item manufacturedor sold by KMDSI must not be used with breathing gas mixtures in excess of 50% oxygen without firstensuring that all gas transporting components have been cleaned for oxygen service, have oxygencompatible soft goods lubricated with an approved oxygen compatible lubricant such as Krytox orChristo Lube grease.

v



Warranty Information

KMDSI warrants every new mask, helmet, or DCS (Dive Control System) to be freefrom defects in workmanship for a period of ninety (90) days from the date of pur-chase. This warranty does not cover rubber parts or communications components.

Should any part be defective, contact your nearest authorized KMDSI dealer. If thereis no dealer in your area, contact KMDSI directly at (805) 965-8538 or FAX (805)966-5761. You must have a return authorization from KMDSI. Upon approval fromKMDSI, return the defective part, freight prepaid to the KMDSI plant. The part willbe repaired or replaced at no charge as deemed necessary by KMDSI.

This warranty becomes null and void if:

1) Your completed warranty card is not received by KMDSI within ten (10) days of purchase date.

2) The Warranty Card is not completely filled our or information on the warranty card is falsified.

3) The product has not been properly serviced and maintained according to the appropriate KMDSI manual and the use of Kirby Morgan Genuine replace ment parts.

4) Unauthorized modifications have been made to the product.

5) The product has been abused or subjected to conditions which are unusual or exceed the product's intended service.

Operational specifications and limitations for surface supplied air diving and scuba diving for United States use, anda separate chart for European Union use are presented on Page 4. The information has been separated because ofthe differences imposed or required by certain regulating bodies. Whenever Kirby Morgan diving equipment is usedin countries that have adopted CE Certification, only CE certified components can be used and all components mustbe part of the tested certified configuration. It is important for the user to understand the rules, regulations, andphilosophy imposed by the governing or regulating bodies whenever diving operations are being planned orconducted. Diving operations must only be conducted within the limits of the operational specifications, and inaccordance with the rules and regulations established by the governing authority in the specific country orgeographical location where the diving operations are being conducted. Technical questions regarding thisequipment should be directed to Dive Lab Inc., of 1415 Moylan Road, Panama City Beach Florida. Telephone 850235-2715, Fax 850-235-0858 e-mail - [email protected]

vi



Contents

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

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

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

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

1.2.1 Mask Specifications ........................................................................................................................... 4

1.2.2 Operationg Specificatins..................................................................................................................... 6

1.3 DESIGN PURPOSE ................................................................................................................................ 7

1.4 ACCESSORIES ...................................................................................................................................... 8

1.4.1 Hoods ................................................................................................................................................. 8

1.4.2 Mask Carrying Bag ............................................................................................................................ 8

1.4.3 Communications ................................................................................................................................ 8

1.4.4 Low Pressure High Flow Hose .......................................................................................................... 8

1.4.5 Manifold Block .................................................................................................................................. 9

1.4.6 Hose Restrictor .................................................................................................................................. 9

1.4.7 Regulator Mount Nut Tools ............................................................................................................... 9

1.4.8 Face Cushion Kit ............................................................................................................................... 9

1.4.9 Equalizing Device, EXO Original only ........................................................................................... 10

1.4.10 EXO Head Protector ........................................................................................................................ 10

1.4.11 Air Inlet Swivel ............................................................................................................................... 10

1.4.12 Tool Kit & Pouch ............................................................................................................................ 10

1.4.13 Over Pressure Relief Valve .............................................................................................................. 10

CHAPTER 2 OPERATING INSTRUCTIONS ...................................................................................... 11

2.1 INTRODUCTION ................................................................................................................................. 11

2.2 FIRST USE AND PRE-DIVE SET UP ................................................................................................. 11

2.3 PRE DRESS-IN PROCEDURE ............................................................................................................ 11

2.4 VISUAL INSPECTION ........................................................................................................................ 11

2.5 CLEAN FACE PORT ............................................................................................................................ 11

2.6 ADJUSTING THE EQUALIZER, EXO STANDARD OR BR ............................................................ 12

2.7 CHECKING REGULATOR FUNCTIONS

AND PREPARING THE EXO FOR USE IN THE SCUBA MODE. .................................................. 12

2.8 WIRELESS COMMUNICATIONS ...................................................................................................... 13

2.9 USING THE EXO IN THE SURFACE SUPPLIED MODE ................................................................ 13

2.10 TESTING THE MANIFOLD BLOCK ................................................................................................. 14

2.11 DIVER'S HARNESS ............................................................................................................................. 15

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2.12 INSTALLING THE MANIFOLD BLOCK ON THE DIVER'S HARNESS ....................................... 16

2.13 BAILOUT BOTTLE (AUXILIARY AIR SUPPLY) ............................................................................. 16

2.14 FIRST STAGE REGULATOR .............................................................................................................. 16

2.15 OVER PRESSURE RELIEF VALVE ................................................................................................... 17

2.16 CONNECTING THE HOSES TO THE MANIFOLD BLOCK ........................................................... 17

2.17 HARD WIRE COMMUNICATIONS ................................................................................................... 18

2.18 RECOMMENDATIONS FOR DONNING AND REMOVING .......................................................... 18

2.18.1 Donning ........................................................................................................................................... 19

2.18.2 Removal .......................................................................................................................................... 19

2.19 PROPER HOOD FIT ............................................................................................................................ 20

CHAPTER 3 IN WATER OPERATIONS ............................................................................................... 21

3.1 INTRODUCTION ................................................................................................................................. 21

3.2 WATER ENTRY .................................................................................................................................... 21

3.3 REGULATOR ADJUSTMENT ............................................................................................................ 21

3.4 SPIDER ADJUSTMENT ...................................................................................................................... 22

3.5 PURGING THE MASK ........................................................................................................................ 22

3.6 LOSS OF BREATHING GAS............................................................................................................... 23

CHAPTER 4 POST DIVE PROCEDURES ............................................................................................ 24

4.1 POST DIVE RINSE .............................................................................................................................. 24

4.2 REASSEMBLING THE MASK AFTER CLEANING ........................................................................ 24

CHAPTER 5 REGULATOR MAINTENANCE ..................................................................................... 25

5.1 GENERAL INFORMATION ................................................................................................................ 25

5.2 ORIGINAL AND STANDARD EXO REGULATOR DISASSEMBLY .............................................. 26

5.3 ORIGINAL AND STANDARD EXO REGULATOR REBUILD ........................................................ 28

5.4 EXO BALANCED REGULATOR DISASSEMBLY ........................................................................... 29

5.5 EXO BALANCED REGULATOR REASSEMBLY ............................................................................ 31

5.6 REGULATOR ASSEMBLY REMOVAL AND INSTALLATION ....................................................... 33

5.6.1 Regulator Assembly Removal .......................................................................................................... 33

5.6.2 Regulator Assembly Installation ....................................................................................................... 33

5.7 EXO REGULATOR ADJUSTMENT ................................................................................................... 35

5.8 LENS REPLACEMENT ....................................................................................................................... 35

5.8.1 Lens Removal ................................................................................................................................. 35

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5.8.2 Lens Installation ............................................................................................................................. 36

5.9 BUCKLE REPLACEMENT ................................................................................................................. 38

5.9.1 Buckle Removal ............................................................................................................................. 38

5.9.2 Buckle Installation .......................................................................................................................... 39

5.10 REPLACING THE FACE SEAL OR FRAME ..................................................................................... 40

5.10.1 Face Seal Removal ......................................................................................................................... 40

5.10.2 Face Seal Installation ...................................................................................................................... 41

5.11 MANIFOLD BLOCK MAINTENANCE ........................................................................................... 41

5.11.1 Daily ............................................................................................................................................. 41

5.11.2 Post Dive Procedures .................................................................................................................... 41

5.11.3 Annual Overhaul ........................................................................................................................... 42

5.11.3.1 Disassembly ........................................................................................................................... 42

5.11.3.2 Disassembly & cleaning of the one way valve ...................................................................... 42

5.11.3.3 Reassembly of the one way valve .......................................................................................... 43

5.11.3.4 Disassembly of the auxiliary valve ........................................................................................ 43

5.11.3.5 Cleaning & Lubricating of the auxiliary valve ...................................................................... 44

5.11.3.6 Reassembly of the auxiliary valve ......................................................................................... 44

5.11.3.7 Reassembly of the Manifold Block ....................................................................................... 45

CHAPTER 6 COMMUNICATIONS ....................................................................................................... 47

6.1 BARE WIRE BINDING POSTS .......................................................................................................... 47

6.2 WATERPROOF CONNECTOR (WPC) ............................................................................................... 47

6.3 WIRELESS COMMUNICATIONS ...................................................................................................... 48

6.4 REMOVING THE COMMUNICATIONS MODULE ......................................................................... 49

6.5 INSTALLING THE COMMUNICATIONS MODULE ....................................................................... 50

6.6 EARPHONE AND/OR MICROPHONE REMOVAL .......................................................................... 51

6.7 EARPHONE AND/OR MICROPHONE INSTALLATION ................................................................. 51

6.8 REMOVING THE WATERPROOF CONNECTOR (WPC) ................................................................ 51

6.9 INSTALLING THE WATERPROOF CONNECTOR (WPC) .............................................................. 52

6.10 REMOVING THE BINDING POSTS .................................................................................................. 52

6.11 INSTALLING THE BINDING POSTS ................................................................................................ 52

6.12 WATERPROOF CONNECTOR (WPC) ASSEMBLY REBUILD ....................................................... 53

6.13 WATERPROOF CONNECTOR (WPC) PIN DIAGRAMS ................................................................. 54

6.14 POST DIVE MAINTENANCE............................................................................................................. 54

EXPLODED VIEWS & PARTS LISTS ......................................................................................................... 56

1

Chapter 1 EXO Full Face Mask Manual


Kirby Morgan Dive Systems, Inc .(KMDSI) is the same corporation (withonly a name change) that startedas the Kirby Morgan Corpo-ration in 1965. Kirby Mor-gan is a registered trade-mark for our products.

Morgan started design-ing and mak ing d iv ingequipment shortly after be-coming a breath-hold diverwhile working as a beach life-guard in the late 1940s. Therewas very little equipment avail-able in those early days so it wasnecessary to make much of his owngear.

During the early 1950's Bev originatedthe Los Angeles (California) UnderwaterInstructor Program for teaching scubadivers and instructors. A short time laterhe started Dive ‘n Surf, one of the firstdiving equipment suppliers to integratescuba diving instruction into the same op-eration as sales and service of equipment.Bev, along with his partners Bill and BobMeistrell, designed and manufactured div-ing equipment whose basis remain as stan-dards in the diving industry today.

In 1957 Morgan sold Dive ‘N Surf tohis partners and spent the next two yearscruising the South Pacific aboard a 60 ft.ketch. After returning from the South Pa-cific, Morgan began diving commerciallyas well as designing and making divingequipment for the commercial market.

The Kirby Morgan Corporation wasformed to manufacture commercial divinghelmets. The copper and brass “heavygear” or “Standard Dress” helmets werethe first helmets manufactured by thecompany. Over the years Kirby Morgandesigned, manufactured and sold morethan thirty five diving helmets and thirtyfour diving masks for commercial and mili-tary divers. Many members of the KMDSIstaff participate as members of the KirbyMorgan design team. It would not be pos-sible for us to supply the commercial,military, scientific, and public servicedivers with our Kirby Morgan DivingEquipment without the team of people thatmake up KMDSI, Inc. (KMDSI).

Bev Morgan, Chairman of the board, KMDSI

A BRIEF HISTORY

2



To: Our Customers

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

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

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

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

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

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

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

express a heartfelt thank you.

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

always be the policy of Kirby Morgan.

Steve Kushner

Preesident, Kirby Morgan Dive Systems, Inc.

3



CHAPTER 1GENERAL INFORMATION

1.1 INTRODUCTION

KMDSI has been designing and manufacturingSCUBA, commercial, scientific, search & res-cue, and military diving equipment for overthirty years. Many of our products have becomethe standard of the industry due to their design,high quality, and outstanding service. The EXO-26 and the EXO-BR are part of this continuingtradition.

The following is a list of features to be foundon the EXO-26 Original, EXO Standard andthe EXO-BR Full Face Masks :

1) Fully adjustable Regulator:The regulator is fully adjustable over a widerange of operating pressures. By simply turningthe Adjustment Knob while diving, you can"tune" your regulator for your type of diving.

DIVING SYSTEMS INTN'L

SANTA BARBARA CA./U.S

.A.

TEMPERED

buckle

mask lens

purge button

spider

regulator adjustment knob

regulator exhaust

mask frame

communications module

Front view of the EXO Full Face Mask.

2) EXOthermic™ Exhaust system:The regulator assembly in the EXO isolates theintake and exhaust chambers from one another.The diver’s own breath assists in reducing ther-mal drain by warming certain areas of the regu-lator. This helps to eliminate freeze ups in coldwater diving.

3) Earphone Pockets:The earphones are allowed to equalize becauseall interior parts of the mask share a commoncavity. There is never a need to adjust theirposition and they are easily accessible.

4) EXOskeleton™:The outer frame, or EXOskeleton, serves sev-eral functions. It protects the face seal and isused to mount external components such as theregulator, lens, and communications.

4



5) Suspension Face Seal:The suspension area of the face seal is attachedto the EXOskeleton by five mounting legs,much like a trampoline. In this way, the faceseals on a soft flexible area rather than a narrowand harder type of seal. This allows the EXO-26to fit different sizes and shapes of faces. Theextra area behind the face seal allows a foampad to be inserted for extra small (narrow) faces.

6) Modular Communications:Microphone and earphones can be easily andquickly replaced. Simply remove the mountingnut and push the entire module to the inside ofthe mask. The earphones and microphone canthen be removed. A spare comm set comes inhandy for rapid replacement in the field ifneeded. If the mask is to be used without com-munications, an oral nasal plug, KMDSI part #320-001, is available to seal the microphonecup in the oral nasal of the EXO Standard or BR.

7) Oral Nasal:The oral nasal on the EXO Standard and theEXO BR full face mask, helps improve breath-ing qualities of the demand regulator and alsoimproves the speech intelligibility of certaincommunications devices available for the mask.It is shipped from the factory with the micro-phone hole punched. All no comm units areshipped with a plastic oral nasal microphonecup plug.This plug should be used when com-munications are not installed.

8) Equalizer:An ear equalizing device (nose block device)is a standard feature on both EXO Standard andBR masks and is used to equalize the diversears. This device has adjustable heights, fittinga variety of noses and faces.

9) Balanced Regulator, EXO BR onlyThe EXO is also available with a balanced regu-lator which has adjustment for a wide range ofoperating pressures. The EXO Balanced Regu-lator has been CE approved in Europe for scubause in conjunction with the KMDSI First StageRegulator and Overpressure Relief Valve.

10) Automatic Defogging, EXO Original only:As the diver inhales, incoming air goes up throughthe inlet tube and down across the lens, defog-ging and ventilating the mask with each breath.

11) Scuba style ear equalizing EXO Original only: A large nose pocket in the mask, allows diversto equalize their ears by pushing back on thenose pocket and pinching. Extra room is pro-vided in the pocket to allow a nose block kit tobe fitted if needed.(see Section 1.4.9)

1.2 SPECIFICATIONS

1.2.1 Mask Specifications

Weight: 4.65 PoundsConstruction: -Exoskeleton / Poly Carbonate, Lexan ® -Face Seal / Neoprene Blend -Regulator Body / Noryl® -Hardware / Stainless Steel & ChromedBrass -O-Rings / Neoprene -Spider / Neoprene

Recommended Lubricant: Silicone Grease,Dow Corning 111

1.2.2 Operating SpecificationsThe CE approved EXO–26-BR complys withEM 250 (edition may 1993). The EXO–26-BRhas been CE tested for scuba use with the KMDSISuperFlow first stage regulator. The EXO-26-BR has also been CE tested for surface suppliedumbilical diving. Regardless of the mode beingemployed, all components used with, or in con-junction with the EXO must be CE approved.

Whenever Kirby Morgan diving equipment isused in countries that have adopted CE Certifi-cation, only CE certified components can beused and all components must be part of thetested certified configuration. It is important forthe user to understand the rules, regulations, andphilosophy imposed by the governing or regu-

5



lating bodies whenever diving operations arebeing planned or conducted. Diving operationsmust only be conducted within the limits of theoperational specifications, and in accordancewith the rules and regulations established by thegoverning authority in the specific country orgeographical location where the diving opera-tions are being conducted. Technical questionsregarding this equipment should be directed toDive Lab Inc., of 1415 Moylan Road, PanamaCity Beach Florida. Telephone 850 235-2715,Fax 850-235-0858 e-mail - [email protected]

Air Supply Pressure:

All Kirby Morgan masks and helmets are de-signed for a maximum working supply pressureof 225 psig (15.5 bar). What this actually meansis the gas train components i.e., intermediatesupply hose, demand regulator and manifoldassemblies are designed to operate at gas supplypressures of up to 225 psig (15.5 bar) above thesurrounding ambient pressure. The regulatoradjustment knob is capable of holding back thispressure, with a little bias in reserve. This is sothe professional working diver can adapt thehelmet or mask to various types of supply sys-tems found on dive stations throughout the world.It is not the intention that the mask or the helmetbe normally operated at the high end pressure225 psig. The normal maximum supply pressureto the EXO-26 BR should be dictated by thedepth and selected in accordance with the speci-fication lists on page6 for the mode of divingbeing employed. Diving with the gas supplypressure higher than the pressure recommendedfor that depth, can sometimes cause the regulatorto be over active resulting in inlet valve pulsa-tion. The specifications on page 6 are split intotwo charts for surface supplied mode and twocharts for scuba mode in order to conform toEuropean conformance requirements and to al-low use in other countries where standardsdiffer. CE (Conformance Europe) is the stan-dard by which man worn diving equipment istested in the Eurpean union. EN-250 was writtento cover recreational diving equipment and is

currently being applied to commercial surfacesupplied diving equipment until a standard forthis equipment can be written. The EN-250Standard does not make exception for the differ-ences between recreational and commercial div-ing equipment and practices. EN-250 does notallow the demand regulator to be adjustable by adiver to a point where a continuous free flow ofgas can be present. Therefore, in order to satisfythe requirements of EN-250 a separate specifi-cations chart was developed (European CE Op-erational Specifications Limitations). When div-ing scuba with the EXO mask, the diver shouldhave an intermediate supply pressure from theSuperFlow first stage at between 135-145 overbottom. This pressure range is more than ad-equate to supply the work of breathing require-ments of EN-250 with the demand regulatoradjustment knob adjusted for minimal inhala-tion effort. Once adjusted in the water, readjust-ment need only be accomplished should thedivers attitude or the current conditions change.The diver should always have the regulatoradjusted for the least inhalation effort based onthe diving conditions, i.e., current or physicalattitude.

When diving in the surface supplied mode, thedemand regulator adjustment knob should bechecked periodically during the dive to ensurethe diver is maximizing breathing performancebased on the delivery pressure. The regulatoradjustment knob also serves another very impor-tant function, in the unlikely event the maskshould develop a continuous leak of water, thebias adjustment knob can be rotated counter-clockwise allowing a slight free flow to developkeeping the mask clear while the diver aborts thedive. This important feature allows the divershands to be free during the accent. This featureis incorporated in all Kirby Morgan helmets andfull-face masks designed for commercial use.

It is important to understand that the regulatoradjustment device is not intended to be a min./max. device, but simply an adjustment that in-creases or decreases spring bias pressure on the

6



inlet valve. The required over bottom pressureshould be applied according to the dive depth.When diving surface supplied the dive shouldstart with the console supply pressure set be-tween 115-135 psig (8-9.3 bar). If the diveproceeds deeper than 100 fsw (30 msw) the overbottom pressure should adjusted on the supplyconsole to be between 135-175 psig ( 9.3 – 12bar) over the bottom pressure (ob) according tothe supply specifications on page 6. When sur-face supplied air diving to the extreme air limitsof 175 –220 fsw, a supply pressure of between175 - 200 psig ob (12-14 bar) should be used.During ascent, the console supply pressure shouldbe reduced corresponding to the decrease indepth. Failure to track the pressure, and back offon the supply pressure during ascent could resultin the demand regulator free flow.Note: Best breathing performance is realizedwhen the supply pressure is tracked for depth.

U.S Operational Specifications and Limita-tions: Surface Supply Mode

- Maximum depth on air –220 fsw (67 msw)

- Maximum depth surface supplied HeO2 – 300fsw (90 msw)

- Work rate - Extreme 75 lpm / rmv

- Umbilical minimum I.D. 3/8” (9.5mm) of onecontinuous length not to exceed (no splices)600’ (182 m)

- Required over bottom supply pressure0 -100 fsw (0-30 msw) 115-135 psig ob (8-9.3bar)

- 100 -175 fsw (135-175 psig ob (9.3-12 bar)

- 175 – 220 fsw (53 - 66 msw) 175-200 psig ob(12 – 14 bar)

- Air/gas supply capable of delivering 4.5 acfm(127.4 bl/min to the manifold block)

European CE Operational Specifications andLimitations : Surface Supplied Mode

- Maximum depth on air – 50 msw (164 fsw)

- Umbilical minimum I.D. 3/8” (9.5mm) of onecontinuous length (no splice) not to exceed 100m(328 ft)

- Work rate - Heavy 62.5 lpm / rmv

- Required over bottom pressure 0 – 30 msw (0 -100 fsw) 8 – 9.3 bar (115 – 135 psig) 30 – 50 msw (100 – 164 fsw) 9.3 – 12 bar (135-175 psig)

- Air/gas supply capable of delivering 4.5 acfm(127.4 bl/min) to the manifold block

U.S. Operational Specifications SCUBA ModeEquipped with KMDSI SuperFlow 1st Stage

- maximum depth tested 198 fsw (60 msw)

- Maximum depth – 190 fsw ( 57 msw) (KMDSI strongly recommends 130 fsw as the maxi-mum depth for recreational and all scuba diving)

- Minimum Intermediate over bottom supplypressure 135 psig (9.3 bar)

- Maximum intermediate over bottom supplypressure 175 psig (11.4 bar) (SF 1st stage maxi-mum shim pressure 155 PSIG)

- Work rate - Extreme – 75 lpm / rmv

European CE Operational SpecificationsScuba Mode

- First stage CE approved KMDSI SuperFlowonly

- Maximum depth air – 50 msw (164 fsw) (KMDSI strongly recommends 39 msw (130 fsw)as the maximum depth for scuba diving)

- Maximum depth tested to on air 50 msw (164fsw)

7



- Minimum Intermediate over bottom supplypressure 135 psig (9.3 bar)

- Maximum intermediate over bottom supplypressure 165 psig (11.4 bar) (SF 1st stage maxi-mum shim pressure 155 psig)

- Work rate - Heavy – 62.5 lpm / rmv

1.3 DESIGN PURPOSE

All the EXO Full Face masks have been de-signed to be used with either SCUBA gear oras part of a surface supplied diving system. Allmodels work exceptionally well in subfreezingconditions and allow the use of a wide range ofsupply pressures, giving the user greater flex-ibility in adapting to various surface supportedsystems. These masks are compatible with mostcommercially available wire type and throughwater communications, making them ideal forcommercial, scientific and search/rescue div-ing. The EXO line has become very popularwith many search and rescue teams diving inwater requiring the added safety and protectionof a full face mask.

EXO Original:The original EXO Full Face Mask has been inproduction for many years. The simple, ruggeddesign has proven very reliable with a mini-mum of maintenance. The Original EXO uti-lizes an inlet tube that directs the incoming gasacross the lens, defogging and ventilating themask with each breath. This full face mask bestsuits the daily working diver that routinelyworks at depths down to 130 FSW in extremelyharsh environmental conditions with minimalpre and post dive maintenance.

EXO Standard:The EXO Standard shares many of the featuresand components found in the Original EXO.The demand regulator body has been changedto allow the use of an oral nasal mask in place ofthe inlet tube. The oral nasal mask slightlyimproves the breathing performance and speechintelligibility of various communications sys-

tems. All internal regulator hardware and softgoods are interchangeable with the EXO Origi-nal. Like the Original EXO, this mask best suitsthe daily working diver that routinely works atdepths down to 130 FSW in extremely harshenvironmental conditions with minimal pre andpost dive maintenance.

WARNING: Do not dive this maskin water containing high concentrationsof petroleum based chemicals. Clean themask using only mild soap and water.

EXO Balanced Regulator:The EXO Balanced Regulator is designed fordeep air diving requiring the highest level ofperformance. Tested by the US Navy for scubaand surface supplied air diving to 190 FSW. Itslow cracking pressure and high flow capabilityallow it to sustain a level of performance onlypreviously achieved by sophisticated and ex-pensive commercial helmets.

This full face mask is best suited for the techni-cal/commercial diver that is capable of perform-ing the required routine maintenance. Mainte-nance of this mask is required more frequentlythan with the other EXO models, but can beaccomplished economically and in less than 15minutes using standard EXO adjustment toolsand procedures.

WARNING: Contaminated waterdiving operations are extremely hazard-ous. They should NOT be attempted un-less all members of the dive team havebeen trained for this type of diving. Youmust check to ensure that every pieceof the diver’s equipment is compatiblewith the contamination to be encoun-tered. If there is the slightest doubt re-garding what contaminants are in thewater, the diver must NOT dive.

8



1.4.1 Hoods

KMDSI manufacturers a hood perfectly tailoredto the EXO-26 masks. It has thinner face sealmaterial on the front as opposed to the thickermaterial of normal types of hoods, for bettercomfort. Order Part #: 310-030 Small, 310-031Medium, 310-032 Large.

Cold Water (CW) versions are also available.These have a large "bib" that tucks into the diverswet suit. Order Part #: 310-035 CW Small, 310-037 CW Medium, 310-039 CW Large

1.4 ACCESSORIES

There are a number of accessories for your EXO Full Face Mask designed to make your diving moreenjoyable and easier. Contact your nearest Authorized KMDSI dealer to order any of the following items.

1.4.3 Communications

The mask may be used with wireless or hardwire communications. Several different typesof communications modules can be ordered forthe EXO. For the cleanest communications, werecommend you use only KMDSI replacementcommunications earphones and microphones.

EXO OriginalPart #: Description315-201 Asembly With Binding Posts315-206 With 4 Pin Waterproof Connector

EXO Standard and BR

Three sizes of hoods are available

1.4.2 Mask Carrying Bag

To protect your mask during storage and trans-port, use our Mask Carrying Bag. The bag holdsyour mask as well as spares. The bag is notintended for shipping your mask as cargo. Or-der Part #: 300-902, Mask Carrying Bag.

.

Part #: Descript315-210 Assembly With Binding Posts315-215 With 4 Pin Waterproof Connector

1.4.4 Low Pressure High Flow Hose

A low pressure high flow hose for the EXO-26or EXO-BR is available. This hose will deliverthe maximum amount of air to the regulator.Order Part #: 255-050, LP High Flow Hose.

9



1.4.5 Manifold Block

If you use the EXO for sur-face supplied diving, amanifold block which has aone way valve and providesfor correct attachment of theumbilical is essential. The auxil-iary valve on the manifold block also controlsthe flow of the bailout supply.Order Part #:300-145 9/16" SCUBA fitting on one way valve300-150 9/16" oxygen fitting on one way valve300-155 #6 JIC fitting on one way valve

1.4.6 Hose Restrictor

The manifold block has extra portsthat allow for attachment of a drysuit inflator hose. Most dry suit in-flation hoses have a built in flow restrictor thatlimits the gas flow to the dry suit inflation valveif the hose gets severed. It also allows a finercontrol of the gas entering the suit. If the hosebeing used is not restricted, the KMDSI flowrestrictor Part # 555-210 must be used.

Caution: Never attach or use a dry suit in-flation hose that is not restricted or does dothave the KMDSI restrictor in place.

1.4.8 Face Cushion Kit

A face cushion kit for the EXO-26 and EXO-BR is available. While the majority of ownersfind the mask provides a watertight seal rightout of the box, some divers with small or nar-row faces may experience trouble getting a com-fortable, tight seal. This optional cushion is de-signed to give divers with smaller faces a betterseal. It is easily installed to the interior of themask. Two velcro tabs secure the cushion in-side the seal, with the ends of the cushion slippedinto the earphone pockets.Order Part #: 325-025, Face Cushion Kit

1.4.7 Regulator Mount Nut Tools

These tools are used for removing and replacing the regulator assembly. The mount nut toolworks on the newer EXO-Standard and EXO-BR as well as the EXO-26's with the original styleregulator mount nuts. These tools are required if an entire regulator rebuild or face seal replace-ment is to be attempted. These two procedures, entire regulator rebuild and face seal replace-ment, can be difficult. KMDSI recommends that these two procedures be done by a factorytrained KMDSI dealer. If you are unsure if your local dealer is qualified to do this repair,call KMDSI for the nearest qualified dealer in your area.Order Part #: 325-650 Deluxe Tool Kit

The EXO Face Cushion Kit

CAUTION: If the EXO is used in thesurface supplied mode the diver must beequipped with a proper bailout systemand one way valve. See Chapter 2 of thismanual for a detailed list of the items tobe included in the bailout system.

325-650 Deluxe Tool Kit

10



1.4.9 Equalizing Device, EXO Original only

If you are using heavy mitts it may bedifficult to grasp your nose for clearingon the EXO Original.To help eliminate this difficulty,KMDSI offers a special nose clearing devicePart# 325-635.

1.4.10 EXO Hard ShellThis hhard shell, Part # 300-010, mounts easilyon all models of theEXO Mask. Thereare reinforced areasfor mounting lightsor small video cam-eras.

1.4.11 Air InletSwivel

Part # 305-036,is supplied on allOriginal andStandard EXOs. It al-lows the regulator hoseto move freely and alignwith the mask inletwithout putting a stress on the hose coupling. Ituses standard SCUBA threads for incomingbreathing air. It may also be used on secondstage scuba regulators and the EXO-BR.

New 200-017Old 200-015

Groove

1.4.13 Overpressure Relief Valve

The KMDSI Overpressure Relief Valve, Part #200-017 is factory adjusted to vent any time thepressure in the low pressure hose connectingthe bailout bottle to your auxiliary valve ex-ceeds 200 P.S.I. It is installed in any of the lowpressure ports in the first stage regulator.

WARNING: Be sure the bailoutregulator is fitted with a relief valve forover-pressurization of the supply hose.A leaky first stage can overpressure thehose, bursting it. This would cause aloss of the entire bailout supply andpossible physical injury to the diver asthe hose whips about. Do not use a highpressure hose, as the system on themask is not designed for high pressure.

The KMDSI Overpressure relief valve hasbeen manufactured in two different flow rates.The original valve had a lower flow rate that thecurrent valve. The current valve has beenmarked in two ways, the first being a groovearound the flats of the hex. Currently the valveis marked with a groove around the top of thebody. These are the same valve, just differentmarking methods.

325-630Tool Kit& Pouch

1.4.12 Tool Kit & Pouch

A special tool kit and pouch are available to store the back up wrench andregulator adjustment tool.Order Part #: 325-630, Tool Kit & Pouch

11



CHAPTER 2OPERATING INSTRUCTIONS

2.1 INTRODUCTION

This section provides the manufacturer’s rec-ommendations on how to use the three EXO FullFace Masks. The use of these diving masks willvary with the type of diving and environmentalconditions. A proper training program in the useof full faced masks must be undertaken prior todiving the mask. Practice using the mask in acalm, clear body of water (pool) before openwater diving. There is a video available fromTeam Visions that goes over many of these basicprocedures. The video, Diving With The EXO-26 Full Face Mask is available from Best Pub-lishing PO Box 30100 Flagstaff Ariz. 86004Ph 800 468-1055.

2.2 FIRST USE AND PRE-DIVE SET UP

When you first receive your EXO Full FaceMask, carefully unpack it and examine it for anydamage that may have occurred during ship-ment. Use the inspection sheet provided to en-sure that no damage has occurred! Read allwarning labels & caution tags.

Be sure to complete the enclosed warranty cardand return to KMDSI as soon as possible. War-ranty claims require that a card be on file atKMDSI 10 days after purchase. Incompletewarranty cards are considered invalid.

2.3 PRE DRESS-IN PROCEDURE

Before dressing in for a dive, an inspection of themask and all related gear should be made toinsure everything is in proper working order.This should be done well in advance of the dive,so any problems or adjustments can be dealtwith. Read and understand this manual beforeyou dive. Chapter 2 tells you the basic operatingprocedures and how to perform the pre-divemask inspections and pre-dive regulator func-tion tests.

2.4 VISUAL INSPECTION

Visually inspect the entire exterior and interiorof the mask.

- The face seal should be in good condition withno cracks, tears, or punctures.

- The spider (head harness) should be intact.Stretch the spider and inspect it carefully forsigns of cracking or tearing.

- Inspect the face port. It should be clean andclear. Anti fog solutions should be applied priorto use.

-Check the wiring for the communications, ifpresent. Make sure the communication modulemount nut is screwed down tight.

-In the EXO Original, inspect the air inlet tubeand make sure it is properly seated on the regu-lator.

-In the EXO Standard or BR, inspect the oralnasal and equalizer and make sure they aresecurely mounted. If the mask does not havecommunications installed, be sure to use a mi-crophone hole plug (320-001) in the oral nasal.

-Check the regulator assembly to ensure that it issecured tightly on the mask frame.

-Check the regulator cover to ensure that it istight on the regulator body.

-With no air to the mask, screw the regulatoradjustment knob all the way out and back in toinsure that it turns freely.

2.5 CLEAN FACE PORT

Remove any sand or debris from the interior ofthe mask and face port which may be inhaledor blown into the divers face, interfering withthe divers vision.

12

Chapter 2EXO Full Face Mask Manual


Under certain conditions, depending upon watertemperature, you may find it necessary to prepthe mask lens to keep it from fogging whilediving. There are a number of commercial de-foggers available for scuba diving which workwell. Follow the directions on the label for use.If no commercial preparation is available it ispossible to use soap. Use a small amount ofliquid soap on a rag and smear a thin film on theinside of the lens. Do not rinse this film off.Apply the soap just prior to entering the water.

2.6 ADJUSTING THE EQUALIZER EXO STANDARD OR BR

There are three different height positions thatthe Equalizer can be adjusted to. Carefully peelthe Equalizer out of the Wire Retainer and re-position it in another one of the molded groovesin the Equalizer. The Wire Retainer can also beslightly bent in one direction or another, up ordown, to get the angle of the Equalizer just right.Insure that the corners of the Equalizer groovesare "snapped" into position on the Wire Retainerso that it does not come loose.

2.7 CHECKING REGULATOR FUNC-TIONS AND PREPARING THE EXOFOR USE IN THE SCUBA MODE.

Attach the low pressure hose that is suppliedwith the mask to the low pressure (L.P.) port onyour 1st stage regulator and then to the mask.Never connect the hose or mask to a high pres-sure (H.P.) port. When attaching the hose to theregulator ALWAYS USE A BACK UPWRENCH ON THE NIPPLE TUBE.

CAUTION: If you are not using theinlet angle fitting, a backup wrench mustbe used on the hex fitting of the regula-tor when tightening. Otherwise the regu-lator may come out of adjustment!

Prior to attaching your first stage regulator toyour tank be sure the regulator adjustment knobon the mask is screwed all the way in. This willprevent the regulator from free flowing when theair is turned on.

Your 1st stage regulator should be equippedwith a submersible pressure gauge. Attach thefirst stage to your tank and turn the air on whileholding the submersible pressure gauge awayfrom you. Once the air is on, check the pressuregauge to ensure you have a full tank.

WARNING: A submersible pressuregauge is considered essential for fullface mask scuba diving. The diver mustplan his dive to avoid running out of airwhile wearing a full face mask. There isno way to safely buddy breathe under-water, use an octopus rig, or snorkel onthe surface while wearing a full facemask. If the submersible pressure gaugeshould fail during the course of a dive,the dive should be terminated immedi-ately.

Check the mask regulator for adjustment andfunction. EXO masks are preset at KMDSI withan intermediate pressure of 135-145 psi. Start-ing with the regulator adjustment knob screwedall the way in, back the regulator adjustmentknob out 3 full turns. There should be no indica-

Always use a back-up wrench when attaching orremoving a hose to the regulator.

13



tion of air flow through the mask if the interme-diate pressure on your first stage regulator is setat around 135-145 psi. Higher first stage regula-tor pressures may cause free flow, but turningthe regulator adjustment knob in should stop theflow. In the unlikely event there is still flow,proceed to the regulator adjustment section inChapter 5 to reset the regulator.

Loosen all the straps on the Spider and hold themask on your face. Take a couple of goodbreaths, breathing slow and soft at first then hardand fast. The regulator should be operating withthe minimal amount of breathing resistance andno free flowing. Any type of an air flow "hiss"should be able to be adjusted out by using theadjustment knob. If the adjustment knob is ad-justed all the way in and the regulator still hisses,see the regulator adjustment section, chapter 5.

Pressing the purge button should cause a fairlystrong air flow into the mask. If there is no flowwhen pressing the purge button, or if breathingis difficult, see the regulator adjustment sectionin chapter 5.

Once you enter the water, the regulator can beadjusted for a variety of diving conditions andpositions just by turning the adjustment knob inor out.

2.8 WIRELESS COMMUNICATIONS

There are several manufacturers that produce awireless communications unit that can be usedwith the EXO Mask. If you are using wirelesscommunications read and follow all manufac-turers instructions for your particular unit.

If you are using wireless communications youshould test the communications by placing thetransducers from both send and receive units ina bucket of water and speaking into the mask.Communications should always be tested priorto the diver entering the water.

WARNING: The waterproof casefor your wireless communications unitshould only be attached to your scubabackpack, NEVER to your weight belt. Inthe event your belt must be dropped thebelt must have a clear drop path andmust not be connected to any other pieceof gear. If this procedure is not followedthe weight belt and wireless electronicscase will be attached to the mask by theconnecting wire.

2.9 USING THE EXO IN THE SURFACESUPPLIED MODE

If you have not been trained in the proper use ofsurface supplied diving equipment we stronglyrecommend that you complete a training coursein the use of this equipment prior to diving sur-face supplied.

Read and understand the Checking RegulatorFunction and Preparing The EXO for use inscuba mode section of this chapter. The basicconnecting instructions of the mask and regula-tor function tests are the same.

Always check the regulator adjustment for properfunction before you enter the water.

14



WARNING: The EXO Mask is notequipped with a one way valve (non-re-turn valve) as supplied from the factory.For safe surface supplied diving, thediver must use a manifold blockequipped with a one way valve. DO NOTCONNECT THE DIVER'S UMBILICAL DI-RECTLY TO THE EXO WITHOUT A ONEWAY VALVE.

The one way valve is a very important compo-nent. It prevents the flow of air out of the maskin the event of a sudden lowering of pressure inthe umbilical supply hose due to an accidentalbreak in the hose or fitting. Not only would theauxiliary air be lost if the one way valve failed(concurrent with a hose or fitting break) but thediver could be “squeezed”, a very serious acci-dent. DO NOT DIVE SURFACE SUPPLIEDWITHOUT A ONE WAY VALVE!

At a minimum, if the EXO is to be used for sur-face supplied diving the following systems andcomponents must be in place and in proper work-ing condition.

1) Air Supply: Either a low pressure compres-sor or high pressure air bottles.(see operatingspecifications, pg 4)

2) Dive Control System: An air managementbox to control the flow of air delivered to thediver or divers (like the DCS 2A or DCS 3 of-fered by KMDSI).

3) Divers Umbilical: Hose bundle consistingof air supply hose, pneumofathometer hose(depth sensing), communications wire and ropeas a strength member.

4) Divers Manifold Block: A metal block thathas a one way valve that the umbilical attachesto, an auxiliary valve that the bail out systemattaches to and L.P. ports for attaching the maskhose, dry suit inflators and other accessories.

5) Bailout System: Consisting of a harness, bailout bottle, first stage regulator with over pres-sure relief valve. This system connects to theauxiliary valve on the divers manifold block as-sembly by a hose.

6) Communications System: Provides hardwire communication between diver and top side.

2.10 TESTING THE MANIFOLD BLOCK

Prior to assembling a bailout system, the oneway valve and auxiliary valve should be testedfor proper function.Equipment Needed:-Manifold Block-Bailout bottle-1st Stage regulator w/octopus and scuba reg hose attached-DCS system with an umbilical supply hose-Bucket of water

The EX0-26 is part of a complete surfacesupplied diving system.

15



A well designed diver's harness

Testing The One-Way Valve

1) With all the accessory holes plugged on themanifold block, attach the SCUBA type regula-tor hose from a first stage regulator that also hasan octopus attached, to the auxiliary valve onthe manifold block assembly. The octopus willbe used for depressurization once the test is con-cluded.

2) Connect the first stage to the bailout bottle,open the auxiliary valve all the way, and pres-surize the system.

3) Place the pressurized manifold block in abucket of water and check the one way valvefor leaks. NO air should leak through the oneway valve or from anywhere else on the mani-fold block assembly. If there is a leak, the oneway valve MUST be rebuilt or replaced.

4) As a secondary test, close the auxiliary valvetrapping pressure inside the manifold block as-sembly and relieve the pressure on the first stageusing the octopus. Disconnect the hose from theauxiliary valve.

5) Quickly open the auxiliary valve by turningthe knob. You should hear the trapped air es-caping through the auxiliary valve.

Testing The Auxiliary Valve

1) With all the accessory holes plugged on themanifold block, attach the umbilical hose to theone way valve.

2) Make sure that the auxiliary valve is closedall the way and pressurize the umbilical.

3) Place the pressurized manifold block in abucket of water and check the auxiliary valvefor leaks. NO air should leak through the auxil-iary valve or from anywhere else on the auxil-iary valve assembly or manifold block assem-bly. If there is a leak, the auxiliary valve MUSTbe rebuilt or replaced.

4) Turn umbilical off and open the auxiliaryvalve to depressurize the system and disconnectthe hose.

2.11 DIVER'S HARNESS

The harness provides an attachment point for themanifold block, tools the diver may use while inthe water, and the "D" ring where the umbilicalshackle connects. The umbilical shackle mustconnect to the strength member of the umbilical.

KMDSI Manifold Block Assembly

Emergency Valve

One Way Valve

Accessory Ports

16



The manifold block attaches to the harness andthe harness is the primary attachment point forthe diver’s umbilical using a shackle. Arrangethe umbilical so it attaches to the harness, then tothe manifold block on the harness. This helpseliminate the possibility of a direct pull on thediver’s mask by top-side. The harness may alsobe used to lift an unconscious diver from thewater and should be of sturdy construction.

2.12 INSTALLING THE MANIFOLDBLOCK ON THE DIVER'S HARNESS

The manifold block assembly is designed to beworn on the diver’s harness. Most divers preferto attach the manifold block to the right side ofthe diver’s harness. The shackle which attachesthe umbilical to the harness “D” ring, is usuallylocated on the left side. After attaching theumbilical to the “D” ring on the left side of theharness, the umbilical is normally routed behindthe diver’s back to the manifold block.

To attach the manifold to the diver’s harness:

1) Remove one of the screws which holds themounting plate on the manifold block body andloosen the other screw to provide enough clear-ance for a harness strap.

2) Swing the plate to one side and position themanifold block on the harness.

3) Swing the plate back into the correct mount-ing position and thread the screw through theplate and into the manifold body.

4) Tighten both screws until the harness is com-pressed between the manifold and mountingplate holding the manifold block assembly inplace.

2.13 BAILOUT BOTTLE (AUXILIARY AIR SUPPLY)

The diver should always dive with a bailoutbottle when diving surface supplied, no matterhow experienced or what the water depth. Should

the diver become unexpectedly entangled un-derwater, or if the top side air supply fails, thebailout bottle may provide the few extra minutesof air the diver needs to deal with the emergencyand get to a safe place.

The size of the bailout bottle should be deter-mined by the water depth, the penetration dis-tance, or the probability of entanglement of thediver. Deeper dives, or distant penetrations willbe made safer with larger bailout bottles. Diveswhich require the use of a larger bailout bottleinclude, but are not limited to, deep dives andpenetration dives..

2.14 FIRST STAGE REGULATOR

The first stage regulator used on the bailoutbottle should be a high-flow unit such as theKMDSI SuperFlow regulator. A submersiblepressure gauge should be connected to the regu-lator to enable the diver to monitor the status ofhis bailout supply. Order KMDSI Part # 305-161, Super Flow 1st Stage Regulator

KMDSI SuperFlow Regu-lator

2.15 OVER PRESSURE RELIEF VALVE

When using the EXO, the first stage regulatorshould be fitted with an overpressure relief valve.This valve is included with the EXO-BR andmust be installed in a low pressure port on thefirst stage regulator. It is also highly recom-mended that the valve be used with the EXOOriginal and EXO Standard anytime a bailoutsystem is used.

17



CAUTION: The first stage regula-tor must be equipped with an overpres-sure relief valve when using the EXO-BR.In the event the first stage leaks there isno way for the pressure in the hose at-tached to the auxiliary valve on the mani-fold block assembly to relieve itself. Thehose may rupture if this occurs leadingto a loss of bailout supply and possiblepersonal injury to the diver.

The purpose of this valve is to allow the regula-tor to bleed off excess pressure should the firststage develop an internal leak. If the first stageleaks and this valve is not present, the pressurebetween the regulator and the auxiliary valveon the manifold block could increase until thehose ruptures. This will cause a complete loss ofthe bailout supply. It could also lead to injury ofthe diver due to the whipping action of the hose.Order KMDSI Part # 200-017, High Flow Over-pressure Relief Valve

The KMDSI Overpressure relief valve has been

2.16 CONNECTING THE HOSES TO THEMANIFOLD BLOCK

After the manifold block has been installed onthe diver’s harness you will need to attach thehoses to route the air supply. Be sure to use thecorrect size open end wrenches, not adjustablewrenches, for connecting the hoses. Adjustablewrenches tend to slip and may damage the brassfittings used on the hoses.

The manifold block has three low pressure portswhich will accept a standard U.S. regulator hoseand one port in line with the one way valve,which will accept a low pressure high flow hose.A low pressure high flow hose attached to thisport and then to the mask will assure the maxi-mum flow of air to the mask regulator.

1) Attach the first stage regulator to the bailoutbottle, but do not turn the air on.

2) Screw the hose from the 1st stage onto theauxiliary valve on the manifold block assem-bly. Tighten this fitting.

low pressure portsfor mask and/or drysuit

bailout supplyconnects here

top-side supplyconnects here

Attachment points for the KMDSI Manifold Blocks

manufactured in two different flow rates. Theoriginal valve had a lower flow rate than thecurrent valve. The newer valve has been markedin two ways, the first being a groove around theflats of the hex. Currently the valve is markedwith a groove around the top of the body. These

are the same valve, just different markings.

18



3) The diver’s umbilical should already be con-nected to the top side dive control system at thistime. Remove the protective cap from the diver’send of the umbilical. Turn the air that suppliesthe DCS (Dive Control System) on. While hold-ing the open end of the diver’s umbilical awayfrom you, slowly turn on the air to the umbilicalat the DCS. This action will blow out any water,dust, or other foreign debris which may haveentered the dive hose. Allow the air to vent fromthe hose for at least 15 seconds.

4) Connect the diver’s air supply hose on theumbilical to the one way valve on the diver’smanifold block assembly. Use the correct sizewrenches and always use a back up wrench.Tighten the fitting only until snug. Do not over-tighten. If too much force is applied to the fittingit will cause the fittings to deform and leak.

5) Connect the hose that was supplied with themask or the low pressure high flow hose to theappropriate low pressure port on the manifoldblock, then to the mask. Remember to alwaysuse a back up wrench on the nipple tube whenattaching the hose to the regulator on the mask.

2.17 HARD WIRE COMMUNICATIONS

When surface supplied diving hard wire com-munications should always be used. There areseveral types that can be used with the EXO.KMDSI makes communications modules withbare wire binding posts and modules with wa-terproof connectors. The communications sys-tem should always be checked and in properworking order before the diver enters the water.See Chapter 6, the chapter on communicationsinstallation, testing, and maintenance.

2.18 RECOMMENDATIONS FOR DONNING AND REMOVING

A course in the procedures for safe diving witha full face mask should be taken and passedbefore any type of diving is performed. Practiceusing the mask in a calm, clear body of water(pool) before using for open water diving.

Become familiar with the way in which the maskattaches and properly fits your face. Because theface seal fits the face well when loosely fitted, itis easy to assume that this is how the mask shouldbe worn. This assumption is incorrect and cancause negative results when diving. Wearing themask with an incorrect adjustment will not allowthe divers face to go far enough into the mask.The air space inside the mask will be excessive,causing a buoyancy and possible problems withthe fit of the seal and oral nasal. The main portionof the face seal is designed to be very flexible andshould be stretched to form a proper seal and becomfortable.

The spider (head harness) and buckles are alsoimportant for proper function of the face seal.The spider legs and rear head cup are allshaped to pull the mask to the face. The headcup should be placed as low as possible toreduce jaw fatigue. The buckles swivel (ex-cept the top) to allow the spider to find itsnatural correct position. Do not try to force thebuckles to swivel completely around. Theyare allowed free but limited movement to keepthe spider from becoming entangled while themask is being handled.

19



2.18.1 Donning

1) Make sure that all other gear is properlydonned, the air is on, and regulator functions andcommunications tests have been done.

2) Make sure all 5 legs of the spider are loosenedall the way.

3) While holding the mask in position by the chincup, begin tightening the spider at the bottomstraps, but not all the way.

4) Make sure the cup of the spider is positioned onthe center of the back of your head. It should be low,but not as low as your neck. support to the mask while standing by for water

entry. Once in the water this top strap may beloosened. Sometimes, if the top strap is too tightand the diver’s hood fills with air while diving,the hood pushing against the top strap may causethe mask to lift up on the face. The spider may bereadjusted during a dive.

2.18.2 RemovalRemoval of the mask is quick and easy.

1) Grasp the bottom of the mask on each sidewhere the buckles are attached.

2) With your thumbs, push the tabs on thebuckles all the way forward. They will stoptraveling once they hit the buckle caps. Hold thebuckles forward.

3) At this point, push the bottom portion of themask away from the face as if it were hinged toyour forehead. This will release the bottom legsof the spider and allow quick and easy removalof the mask.

5) Next tighten the top two straps above thetemples. Alternate between top and bottom strapsuntil the face is positioned properly and snuglyinto the mask.

The mask is usually the most comfortable whenyour nose is partially into the nose pocket. Thetop center strap can be tightened slightly to give

Tighten the upper spider legs next.

Tighten the lower spider legs first

20



2.19 PROPER HOOD FIT

The type of hood that a diver chooses may havedirect bearing on the fit and comfort of the EXO.Excess material on the chin and or jaw will keepthe mask from positioning properly and possiblycause jaw fatigue. This may also prevent thediver’s face from getting far enough into themask for equalizing by pinching the nose.

When using a dry suit with a latex hood, noadjustment should be needed. However, if thehood covers too much of your face, it may benecessary to trim a small amount of rubber offthe chin on the hood. If using a neoprene wet suithood, you may want to trim material from thecheek bone downward to under the front part ofthe chin.

The EXO is easily removed by the diver when necessary.

To properly trim your hood, use the followingprocedure:

1) With the hood in position on your head, donthe mask as outlined in this chapter.

2) Have someone bend the earphone pocketsforward and start marking the hood at the edge ofthe face seal, starting at the cheek bone area, thengo down under the chin and up the other side tothe opposite cheek bone area.

3) Remove the mask and hood. Leave approxi-mately 1/4" extra material from the line markedand trim the excess material away.

4) Your hood should now work very well withthe mask. Because the face is in a dry air cavitybeing warmed by body heat, hood material onthe face is not needed to keep the face warm.

KMDSI makes a hood tailored to the EXO (seeaccessories p.6) It must be trimmed in the samefashion as above. The face seal area is a thinnertwo sided skin neoprene for a superior seal.

Note:A small hole can be punched in the top of thehood to relieve any build up of air inside. Put thehole or holes so that they are to either side of thetop spider strap.

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3.1 INTRODUCTION

This section deals with the different functionsand adjustments that are possible after entry intothe water. Some divers may be satisfied with thefit and function of the mask as it is set up top side,or it may be easily adjusted in the water ifnecessary.

3.2 WATER ENTRY

Many methods of entry into the water are pos-sible using the EXO-26 or EXO-BR , but a fewimportant points should be noted. When usingthe stride entry, the bottom 7 holes in the exhaustwhisker should be covered to prevent any turbu-lent water from flowing past the exhaust valve.The demand regulator adjustment also servesanother important function, in the unlikely eventthe mask should develop a continuous waterleak, the diver can back out on the demandregulator adjustment knob until the regulatordevelops a free flow of gas. The free flow of gaswill displace any incoming water. The diver thencan abort the dive with both hands free.

If you roll into the water backwards, turn yourhead to one side before entering to prevent waterfrom washing past the face seal to the interior ofthe mask. In the event water does enter the mask,keep the regulator positioned low and simplypress the purge button to remove the water.

3.3 REGULATOR ADJUSTMENTThe regulator adjustment knob should alwaysbe adjusted for minimum breathing resistance.Prior to entering the water, adjust the regulatoradjustment knob out until a slight fee flowdevelops and then adjust it in until the free flowdisappears. If diving with scuba gear no furtheradjustment should be needed. If diving surfacesupplied, the adjustment knob allows the diverto make adjustments for variations in supplypressures. During the course of the dive the divershould periodically turn the adjustment knob out(counter clockwise) until the regulator develops

a slight free-flow, then turn the knob in(clockwise) until the regulator free-flow juststops. This will ensure the diver is always takingadvantage of the best performance for theavailable delivery pressure. The regulatoradjustment knob can also be used to compensatewhen working in various positions and divingin currents.

The most noticeable difference in breathing re-sistance can be found in a face up position.Resistance increases with the regulator dia-phragm in this position.

If the regulator adjustment knob is adjusted allthe way in and breathing resistance is high, it issometimes possible for small amounts of waterto get past some areas of the face seal when themask is not fitted properly. Any leakage whichdoes occur usually enters in the temple area.Backing out on the adjustment knob will de-crease the spring bias tension on the roller lever,allowing the diaphram to move the roller leverwith less inhalation effort. This will help preventwater from being drawn in around the face seal.If leakage still persists, a face cushion kit isrecommended. Fine tuning the regulator shouldbe common practice if you maintain a certainposition for any length of time and then changepositions. If you are working in a face downposition and the regulator adjustment knob isadjusted too far out, the regulator may free flow.The adjustment knob should be turned in to stopany excess air flow.

CHAPTER 3IN WATER OPERATIONS

22



Using the purge button to clear a flooded mask.

3.4 SPIDER ADJUSTMENT

The mask can be repositioned while in the water,by loosening, repositioning and retightening thespider legs. The large tabs on each buckle pro-vide this easy adjustment. It should also be notedthat the buckle travel is limited to allow easyrelease.

The top leg of the spider can be loosened once inwater. It is possible for the top leg to be too tightwhich will cause the mask to be pulled up too faron the face. The main purpose for the top leg ofthe spider is to provide on deck support of themask. Some divers may prefer the support of thetop leg while in the water, too.

CAUTION: Proper hood fit and spi-der adjustments are needed for the maskto fit comfortably and function correctly.

The mask is easily adjusted underwater.

3.5 PURGING THE MASKIf the mask is removed and then replaced under-water, it must be cleared of water (purged). Thisis done by simply holding the mask firmly on theface, keeping the regulator in a low position, anddepressing the purge button. A momentary slightoverpressure will be felt, followed by completeremoval of all water from the interior of themask. A mask completely filled with water shouldtake no more than 3 seconds to completelypurge.

WARNING: In the unlikely event themask should fill with water, depressingthe purge button should clear the mask.In the event of a continuing flood, theadjustment knob should be turned outto cause a regulator free flow. The divershould then immediately assume a facedown position in the water to preventthe mask from flooding again. At thispoint the diver should exit the water im-mediately.

23



In the unlikely event the mask should develop acontinuous leak, the diver should maintain a faceforward and slightly down position, and slowlyturn out (counter-clockwise) on the demand regu-lator adjustment knob (9) until and a steady freeflow of gas develops. The free flowing gas willdisplace the water and keep the mask cavity clear.The diver should then immediately notify topside(if equipped with communications) and abort thedive.

CAUTION: If using scuba, use of asteady flow will rapidly deplete the scubacylinder. Adjust the free flow so that theflow of gas needed to keep the water out isminimal. Continuous leakage of water intothe mask is not normal. Do not continue adive if continuous water leakage is present.

3.6 LOSS OF BREATHING GAS:

SCUBA: When diving scuba with a full-face maskit is essential that the scuba is equipped with anaccurate submersible pressure gauge. If the gassupply is exhausted, there are no provisions forbuddy breathing with the mask on the face. If theregulator starts breathing hard or quits breathing,check the air supply. If the gage indicates airpressure in the cylinder, back out on the demandregulator adjustment knob until a free flow is estab-lished and abort the dive. If there is no air in thecylinder, immediately abort the dive.

Surface Supplied Mode:If surface supply gas is interrupted or fails, the divershould immediately open the emergency valve onthe manifold assembly. If gas is still not restored,the diver should back out on the demand regulatoradjustment knob (counterclockwise) to establish asteady flow, notify topside, and abort the dive.Regardless of the cause, whenever a supply of gasfails even if it is restored the diver should abort thedive and the problem should be thoroughly inves-tigate as to the cause of the failure. Diving shouldonly proceed after all problems are rectified.

24



The regulator adjustment knob should be backedall the way out for storage.

CHAPTER 4POST DIVE PROCEDURES

4.1 POST DIVE RINSE

The mask should be rinsed thoroughly with freshclean water and the post dive procedures followedafter each day of diving.

1) If the mask is equipped with communications,remove and perform maintenance in accordance withChapter 6 of this manual.

2) The EXO-BR should be rinsed with the regulatorhooked up and pressurized. This will prevent waterfrom entering the balance chamber during rinsing.The EXO-BR requires routine cleaning and lubrica-tion prior to periods of inactivity. This is due to theexacting tolerances of the balanced inlet valve. Ifinactivity longer than one week is planned, the inletvalve should be removed, cleaned and relubricatedprior to storage. If the mask is used daily, this main-tenance should be performed monthly. Refer to Chap.5, page 26.

3) Thoroughly rinse the entire interior and exteriorof the mask with fresh clean water. Insure that allthe sand and debris are removed from between theEXOskeleton and mask seal and all the salts are re-moved from the regulator.

4) Purge the regulator and try to get as much waterout of it as you can, then blow dry the mask withcompressed air or let air dry completely.

5) Disconnect the regulator and turn the adjustmentknob all the way out.

6) Lay the mask face down so that no water willcollect in the ear pockets. DO NOT dry the mask orlet it sit in the direct sun light for long periods oftime, as this will degrade the rubber.

4.2 REASSEMBLING THE MASKAFTER CLEANING

Insure that all the parts and assemblies are com-pletely dry before assembling or storing.

1) Install the oral nasal and equalizer if they wereremoved.

2) If so equipped, install the communications inaccordance with Chapter 6. If no communications

are used, the hole in the microphone cup in the oralnasal must be plugged. Use KMDSI oral nasal mi-crophone plug, part # 320-001.

3) When storing the mask, make sure the regulatoradjustment knob is backed all the way out. This willprevent wear to the regulator seat and lengthen itsuseful life. Store the mask with the earphone pocketsfacing straight back or inward. This will help therubber keep its shape better than stored with theearphone pockets facing outward.

All the O-rings should be replaced at least once ayear. The inlet valve on the EXO Standard and Origi-nal should also be replaced once a year. The EXOBR inlet valve will not require annual replacementas long as it is routinely cleaned and lubricated andthere is no evidence of corrosuion or damage. Allthe EXO masks were designed for minimal mainte-nance. It is important to carefully inspect the maskafter post dive maintenance to ensure it has beenproperly cleaned and dried prior to storage.

Your entire regulator should be rebuilt every yearor 400 operating hours, whichever comes first. Toperform an entire regulator rebuild (including theexhaust valve) or to replace the face seal, the regu-lator mounting tools must be purchased.

25



5.1 GENERAL INFORMATION

All EXO demand regulators are initially adjustedand preset at the D.S.I. factory using an interme-diate pressure of 135-145 P.S.I. The EXO regula-tor is an adjustable second stage regulator. Thisallows the masks to work well over a wide rangeof pressures and diving conditions. When regula-tor parts need changing, cleaning, or the regulatorhas gone out of adjustment, read all of the follow-ing and refer to the diagrams and blowapartsto become familiar with all parts and termsassociated with the areas of the mask prior toany disassembly of the regulator. There are twotypes of EXO regulator covered in this manual,the EXO original/standard and the balanced, withdisassembly and rebuild sections for each.

The EXO Standard and Original masks should beoverhauled every year or every 400 operatinghours. This includes O-ring and inlet valve re-placement. The EXO-BR demand regulator shouldbe dissembled, cleaned, and inspected every 100hours of use or once a year, whichever comes first.The inlet valve on the EXO-BR normally seesvery little wear, so replacement is only neededafter every 600 hours of use or every twenty-fourmonths, whichever comes first. Because the EXO-BR inlet valve is of a pneumatically balanceddesign, the EXO-BR demand regulator inlet valve(1) requires more frequent cleaning and lubrica-tion than the EXO Standard and Original. Theinlet valve should be removed and both the inletvalve and the main tube (3) should be cleaned andinspected at least once a year or every 100 hours,whichever comes first. After cleaning and in-specting the inlet valve, the O-ring (2) should belubricated. This procedure can be complete without removing the demand regulator assembly.Normal overhaul does require replacement of allregulator O-rings.

Normal annual overhauls of the EXO demandregulators DO NOT require you to completelyremove the regulator can body from the mask.

Removing and reinstalling the regulator is a dif-ficult procedure, and will require the KMDSIregulator mount nut tool. Complete mask dis-assembly is possible provide the user has theproper KMDSI tools. However, it is recom-mended that this service be performed by a fac-tory trained KMDSI Dealer. Contact KMDSIat (805) 965-8538 for your nearest factorytrained service center.

Note: If you are doing a regulator rebuild andare changing the exhaust valve, it is possibleto do a replacement without completely remov-ing the regulator. Follow the directions for dis-assembly of the regulator. Then follow the di-rections for removing the regulator, but insteadof taking the regulator mount nut completelyoff, only loosen it enough for the regulator tobe pulled slightly forward, then pull the whis-ker off of the regulator body to access the ex-haust valve. Replace the exhaust valve makingsure that it is facing the right direction andseated correctly. Then put the exhaust whiskerback on and follow the directions for installingthe regulator. Following this procedure savesyou from having to remount the regulator inthe mask seal and frame and from possible crossthreading of the regulator body while puttingthe regulator mount nut back on.

CAUTION: Use only Kirby Mor-gan original replacement parts when re-pairing your mask. The use of othermanufacturer’s parts will interfere withthe performance characteristics of yourequipment and may jeopardize yoursafety. Additionally, any substitutionswill void any warranties offered byKMDSI. All of the spare parts listed onthe blowapart drawings were specifi-cally manufactured by KMDSI for useon the EXO. When ordering spares, al-ways insist on KMDSI original parts.

CHAPTER 5REGULATOR MAINTENANCE

26



Always use a back up wrench on the main tube whenloosening the packing nut to prevent possible damage tothe regulator.

The EXO Original and Standard regulator

5.2 ORIGINAL AND STANDARD EXO REGULATOR DISASSEMBLYTools required:13/16" open end wrench, 5/8" open end wrench

1) Unscrew the regulator cover assembly andremove the washer and diaphragm.

2) Back out the adjustment knob far enough toallow a 13/16" open end wrench to fit onto thepacking nut. Place a 5/8" open end wrench, or

The adjustment assembly is removed afterthe packing nut is loosened.

the wrench provided with the mask, on the op-posite side of the main tube. This will be usedas a back up wrench to keep the main tube fromspinning when loosening the packing nut.Loosen the packing nut and unscrew the adjust-ment knob assembly from the regulator.

27



3) Position the mask so that the adjustmentknob end is pointed down and shake out thespring and spacer.

4) Push the adjustment side of the main tubeabout 3/8" into the regulator body. This will beenough to allow the roller lever to be removedfrom its slot. Remove the roller lever.

5) Once again position the adjustment knobend of the main tube downward and gentlyshake the mask to dislodge the inlet valve. Re-move the inlet valve.

6) Keep pushing the main tube through theregulator body until the horseshoe is centeredin the regulator body. Remove the horseshoefrom the main tube by sliding it off.

7) Remove the main tube by continuing to pushit through the regulator body

8) Loosen the adjustment lock nut on the nippletube and unscrew the nipple tube from the maintube.

Inspect the nipple tube seating surface for dings,nicks, and wear. You should be able to feel anyirregularities with your fingernail. If the tube isdamaged it must be replaced.

9) Inspect and clean all parts. All the O-ringsshould be replaced at least once a year. Lubri-cate all O-rings lightly with silicone grease. In-spect the seat on the inlet valve. There shouldbe no cuts or nicks in the seat. Replace inletvalve if seat is damaged.

Remove the spring and spacer.

Push the maintube out enough toallow the leverarm to beremoved.

Remove the roller lever arm.

Gently shake out theinlet valve.

28



5.3 ORIGINAL AND STANDARD EXOREGULATOR REBUILD

After all parts have been cleaned, inspected, andlubricated lightly with silicone grease as needed,make sure all O-rings are in their appropriateplaces.

1) Install the nipple tube into the main tube.Make sure the adjustment locknut is on thenipple tube before screwing it in. Screw thenipple tube all the way in then back it out about1/8". Snug the lock nut up against the main tube.

Loosen the adjustment lock nut on the nipple tube and unscrewthe nipple tube from the main tube. Inspect the nipple tube seat-ing surface for dings, nicks, and wear. You should be able to feel

any irregularities with your fingernail.

2) Slide the main tube into the regulator body.The main tube should be oriented so that the airinlet hole (the big one in the middle) will befacing the inside of the mask. Keep sliding thetube in until the horseshoe area of the main tubeis centered in the regulator body.

3) Slide the horseshoe into its place on the maintube from inside the mask.

4) Keep pushing the main tube in until it is about3/4 of the way in.

5) Reinstall the inlet valve, rubber seat first, inthe main tube. Tilt the mask and gently shake ituntil the skinny part of the inlet valve is alignedwith the roller lever slot in the main tube.

6) Install the roller lever and push the main tubethe rest of the way through. Make sure that theroller lever is caught in the skinny area of theinlet valve. Make sure that the exhaust whiskeris properly seated on the main tube

Make sure that the exhaust whisker is properly seated onthe main tube.

7) Reinstall the spring and spacer, spring first,into the main tube.

8) Reinstall the adjustment knob assembly andtighten the packing nut. Remember to use a backup wrench on the other end of the main tubewhen tightening the packing nut to prevent themain tube from spinning. Tighten packing nutto 40 inch pounds of torque.

29



Unscrew the adjustmentknob assembly from theregulator.

Note: If the knob is out too far when tighteningthe packing nut, the nut will not seal or tightencompletely.

9) Screw the adjustment knob in about half way.Place the diaphragm in the regulator then holdthe mask so that it is facing up. Loosen the locknut on the nipple tube and very slowly turn thenipple tube counter clockwise until you noticethe roller lever hit the bottom of the diaphragm.Adjust it so that the roller lever is just barelybelow the diaphragm. Finger tighten the lock nutup against the main tube.

10) Replace the diaphragm washer and screw inthe regulator cover assembly and follow theRegulator Adjustment procedures in section 5.7.

5.4 EXO BALANCED REGULATOR DIS-ASSEMBLY

Tools required:1 3/16" open end wrench1/8" open end wrench5/8" KMDSI back up wrench.All plastic or brass handled tube brushNylon tooth brush

The inlet valve of the EXO-BR requires frequentcleaning and lubrication due to the exactingtolerances of the inlet valve mechanism. Oncefamiliar with this procedure the task can beaccomplished in about 10-15 minutes. Thefollowing procedure is intended as a routinemaintenance of the inlet valve mechanism. If a400 hour or annual overhaul is being done,replacement of all O-rings is required. If a 600-hour or 24 month overhaul is being done,replacement of all O-rings is required.

A few words of CAUTION!Use only mild detergents such as hand dishwashing detergent. Use only a tube brush thatdoes not have an exposed metal tip or an allplastic brush. A tube brush with hard metalcomponents could scratch the chrome surface ofthe balance chamber. If O-rings are to beremoved, use only a plastic pick. Use of a metalpick could scratch delicate surfaces.

1. With mask disconnected from a pressuresource, remove the hose from the nipple tube. Ifthe nipple tube is equipped with the swivelremove the swivel from the nipple tube.

2. Unscrew and remove the regulator diaphragmcover, then remove the thrust washer anddiaphragm.

3. Back out the regulator adjustment knob farenough to allow the 1 3/16" open end wrench tofit on to the packing nut. Place the 5/8" KMDSIwrench on the hex on the opposite end of themain tube, then loosen the packing nut andremove the regulator adjustment knob. Shakethe mask, and allow the spring and two springspacers to drop free.

4. Using the thin KMDSI wrench on the maintube body and a standard 5/8" wrench on thenipple tube jam nut, loosen the jam nut.

Always use a back upwrench when looseningthe Adjustment KnobAssembly

Remove the rollerlever arm.

30



Carefully unscrew and remove the nipple tubefrom the main tube. Be careful not to drop orbump it as the seating surface is very delicateand can be easily damaged. Set it aside where itwill not be damaged.

5. Carefully push the adjustment knob side ofthe inlet tube into the regulator bodyapproximately 1/4" to 3/8". This will allow thehorseshoe retainer to be removed. After removalof the horseshoe, the roller lever can be removed.

6. Shake out the inlet valve, it will drop throughthe inlet nipple side of the tube. At this point thecleaning and maintenance can be performedwithout further disassembly, However, shouldyou desire, the tube can be taken out completely.

7. Mix a solution of mild hand dishwashingdetergent and warm water. Using the tube brush,carefully clean the balance chamber locatedapproximately 1 1/2" in from the center of themain tube in the direction of the regulatoradjustment knob end. The balance chamber ismachined to exacting tolerances and onlyrequires a gentle brushing. USE EXTREMECAUTION WHEN CLEANING THEBALANCE CHAMBER. A brush with hardmetal components could damage the balancechamber.

8. If the main tube was removed, clean the tubeusing the toothbrush. Gently clean the exteriorsurface, working the bristles in and around theO-ring grooves of the two static O-rings.Thoroughly rinse with fresh water and blow drywith compressed air. Inspect the exterior of thetwo O-rings for damage. Replace if any damageis found.

9. Using the toothbrush and soapy water,carefully scrub the inlet valve to remove all dirt,salts, and old lubricant. Normally, it is notnecessary to remove the inlet valve O-ring inbetween annual overhauls, as long as the O-ringgroove is not heavily corroded. If heavy

corrosion is present, the O-ring should beremoved using a plastic O-ring pick.

CAUTION: Use of a metal pick willscratch the anodized surface of the in-let valve allowing corrosion of the inletvalve body.

Using the nylon toothbrush, carefully clean theinlet valve by working the bristles carefully inand around the O-ring and O-ring groove. Rinsethoroughly with fresh water and blow dry withcompressed air. Carefully inspect the O-ringgroove by gently rocking the O-ring from sideto side. The O-ring groove should be free ofpitting and corrosion damage. Carefully inspectthe soft seat surface for cuts, nicks andabrasions. Normally, the soft seating area willhave a slight round depression where it laysagainst the metal seat. This is normal. Blowlightly through the 1/8" balance tube shaft withyour lips to insure air passes freely through theinlet valve. Replace the inlet valve if no flowis detected, or if any corrosion or soft seatdamage is apparent.

10. Clean the regulator adjustment knob shaftand O-ring using the soapy water andtoothbrush. Rinse thoroughly and blow dry.Carefully inspect the O-ring for wear anddamage replace if necessary.

11. Clean the inlet nipple tube using thetoothbrush and soapy water. Gently work thebristles in and around the O-ring surfaces. Rinsethoroughly with fresh water and blow dry.Carefully inspect the O-rings for damage,replace if necessary. Carefully inspect theknife-edge of the nipple tube for nicks anddings. The knife-edge must be free of anydamage. You should be able to feel anyirregularities with your fingernail. If the tubeis damaged it must be replaced. After all partshave been cleaned and inspected. Lightlylubricate all O-rings and O-ring surfaces withsilicone grease. Work the grease into the O-ring grooves then rotate the O-rings to spreadthe lubricant and wipe off any excess.

31



5.5 EXO-BR REGULATOR REASSEMBLY1) After all parts have been cleaned, inspected,and lubricated lightly with silicone grease asneeded, make sure all O-rings are in their ap-propriate places.

2. If the main tube was completely removedfrom the regulator body, reinstall it by sliding itinto the regulator body. The "B" that is machinedinto the main tube at the nipple end should befacing the front of the mask. Keep sliding thetube in until the horseshoe area of the main tubeis centered in the regulator body. If the maintube was not removed it will already bepositioned for acceptance of the horseshoeretainer.

4) Slide the inlet valve into the main tube fromthe nipple tube side, sliding it in until the inletvalve is seated into the tube.

5) Slide the roller lever into the roller lever sloton the main tube. Make sure that the inlet valveis caught by the roller lever and push the maintube all the way into the regulator body. Makesure that the exhaust whisker is seated in thegroove around the main tube at the nipple tubeend.

6) Install the nipple tube into the main tube.Make sure the adjustment lock nut is on thenipple tube before screwing it in. Screw thenipple tube all the way in then back it out about1/8".

Install the Nipple Tube.Slide the horseshoe into place on the main tube frominside the mask.

Install the inlet valve.

The "B" on the tube should be facing the front of themask.

3) Slide the horseshoe into place on the maintube from inside the mask.

32



EXO Standard & Balanced RegulatorAssembly Mount Diagram

EXO Original RegulatorAssembly Mount Diagram

Install the spacers and spring.

7) Place the spacer, spring, and spacer togetherand slide this assembly into the main tube fromthe adjustment knob end. Make sure that thespacers go in straight and move freely.

8) Reinstall the adjustment knob assembly andtighten the packing nut. Always use a back upwrench on the other end of the main tube whentightening the packing nut to help prevent the

main tube from damaging the regulator body.Tighten the packing nut to 40 inch pounds.

Note: If the knob is out too far when tighteningthe packing nut, the nut will not seal or tightencompletely.

9) Screw the adjustment knob in about 1/2 way.Place the diaphragm in the regulator then holdthe mask so that it is facing up. Very slowly turnthe nipple tube counter clockwise until you no-tice the roller lever hit the bottom of the dia-phragm. Adjust it so that the roller lever is justbarely below the diaphragm. Finger tighten thelock nut up against the main tube.

10) Install the diaphragm, washer and regulatorcover assembly. Follow the Regulator Adjust-ment procedures, section 5.7.

33



5.6 REGULATOR ASSEMBLYREMOVAL AND INSTALLATIONTools required:3/8" ratchet with an extension.EXO Tool Kit, Deluxe. KMDSI Part #325-650.

This can be a difficult procedure. It is recom-mended that this procedure be done by a fac-tory trained KMDSI dealer. If you are going toattempt this procedure read and understand thisentire section before you start disassembly!

Note: If you are doing a regulator rebuild andplan to change the exhaust valve, it is pos-sible to replace the valve without complete re-moval of the regulator. Follow the directions fordisassembly of the regulator. Then follow thedirections for removing the regulator, but insteadof taking the regulator mount nut completelyoff, only loosen it enough for the regulator tobe pulled slightly forward, enough to pull thewhisker off the regulator body to access the ex-haust valve. Replace the exhaust valve makingsure that it is facing in the right direction andseated correctly. Then put the exhaust whiskerback on and follow the directions for installingthe regulator. Following this procedure savesyou from having to remount the regulator in themask seal and frame and from possible crossthreading of the regulator can while putting theregulator mount nut back on. If the threads onthe regulator can are damaged the can MUSTbe replaced.

5.6.1 Regulator Assembly Removal

1. Remove spider and communications mod-ule. See chapter 6.

2. Remove the inlet tube of the EXO originalor cut the tie wrap and remove the EXO Stan-dard or BR oral nasal and equalizer.

3. On the EXO Standard or BR, remove thescrews and washers that hold the wire retaineron and remove the wire retainer.

4. Install the regulator mount nut tool on a 3/8"ratchet with an extension.

5. With the mask face down in your lap, placethe regulator mount nut tool in the grooves ofthe regulator mount nut. Remove the regulatormount nut.

6. Remove the mount ring.

7. Gently pull straight out on the regulator as-sembly, removing it from the mask.

8. Remove the Regulator Mount Washer fromthe inside of the mask.

5.6.2 Regulator Assembly Installation

1) Inspect the Mask Seal in the regulator areafor tears or holes and replace if damaged. Insurethat the Mask Seal is properly mounted into theFrame. This is what seals the regulator to themask. It is very important that the seal in thisarea remain correctly seated in the frame and doesnot get pushed through during all phases of in-stallation.

2) Once the seal is correctly in place, lightlylubricate the inside of the regulator mounting holein the mask seal with silicone grease. Do not getgrease between the mask seal and the frame. Ifthe grease gets between the frame and the maskseal, the mask seal will become unmounted andpush through more easily when installing theregulator. Lightly grease the threads on the regu-lator body.

3) Holding the mask in one hand and the regula-tor assembly in the other with the exhaust whis-ker openings pointed down to the bottom of themask, insert the regulator assembly into the mask.Hold the regulator at a slight angle when youfirst start to push it through the opening thenstraighten it out as you go in. Start the threads ofthe regulator partially in on one side of the open-ing then work it into the hole. On the inside ofthe mask use your finger tips to support the MaskSeal to keep it from being pushed to the insideof the Frame.

Once the regulator is in, visually inspect the MaskSeal on the inside of the mask and make surethat the mask seal did not get pushed through

34



and that it is still correctly seated on theframe. If the seal has been pushed through, takethe regulator out and try again.

Do Not Cross Thread. It is easiest to start themount nut by hand. Put the nut on the regulator,slowly turn counterclockwise until you feel thenut drop onto the threads, and then gently threadon by hand as far as possible to insure that itdoes not cross thread. Cross threading can dam-age the regulator can. If the threads are dam-aged in any way the can must be replaced. Oncethe mount nut is on correctly, start tightening.Once again, check and make sure that the ex-haust whisker is properly seated in the framebefore final tightening. Tighten the regulatormount nut to 100 Inch Pounds.

7) Put the Mount Ring Adjustment tool on theratchet extension and mount the tool into themount ring.

Make sure that the mask seal did not get pushed through

Good

Bad

Once the regulator is properly seated, inspectwhere the Exhaust Whisker meets the Frame andmake sure that the Whisker is properly seatedinto the groove of the front of the regulatormount area on the frame.

4) Lightly lubricate the regulator mount washerand install it on the regulator.

Turn the mount ring until it is horizontallyaligned (see above).

8) On a EXO Standard or BR, reinstall the wireretainer with the screws and washers.

9) Reinstall the Inlet Tube (EXO Original) or:

10) Reinstall the oral nasal mask( Exo BR) andproperly align the nose cavity. Make certain theround mount lip is properly / completely insertedinto the mating groove found on the regulatororal nasal mount nut.

11) Install the new tie wrap part #: Insert the tailof the tie wrap into the head and pull it throughabout 1.5” This will allow enough circle to fitover everything during installation. Begin in-stallation by carefully folding the oral nasalmask in on itself only enough to allow the tiewrap to pass over the outside of it. Be carefull notto displace the oral nasal from the groove of theregulator mounting ring. Double check makingsure the oral nasal is seated in the groove. Care-

5) Place the mount ring inside of the mountnut. The pressed in insert on the mount ringshould have the bumps facing the regulator.

6) Thread the Mount Nut onto the RegulatorAssembly. The mount nut must go on straight.

35



fully begin tightening the tie wrap, while push-ing it down against the regulator mount nut.Direct the head of the tie wrap towards thechannel inside the main mask cavity, found atabout the 9:00 O’clock position. Before the tiewrap is closed tight, check again to be sure theoral nasal is still in the groove. Hold the tie wrapdown against the mount nut and tighten withneedle nose pliers. Snip off any excess tie wrapmaterial as close to the head as possible.

Check the installation by lightly tugging at theoral nasal. It should remain seated. If it pullsfree, repeat steps 4 thru 9 with a new tie wrap.

If the installation tests good, reinstall the micro-phone into the pocket in the oral nasal. Re installthe nose equalizing device onto it’s mount.

10) Reinstall the communications in accordancewith Chapter 6.

5.7 EXO REGULATOR ADJUSTMENT

NOTE: After any work is done on the EXORegulator, it must be checked for proper ad-justment before any diving is done! If a newInlet Valve is installed, the adjustment knobshould be turned in completely and allowedto sit for 24 hours before attempting any regu-lator adjustment. In the event you must diveimmediately, you will have to readjust themask after allowing the valve to seat prop-erly over a 24 hour period.

1) Turn the adjustment knob all the way in thenback it out 3 full turns

2) Make sure the cover assembly is properlytightened onto the regulator.

3) Hook up an air supply. The nominal supplypressure is 135 psi - 145 psi. Turn air supply on.

4) Place the spanner wrench across the centerof the purge button so that the bump in themiddle of the wrench depresses the purge but-ton.

5) Adjust the regulator by holding the spannerwrench against the purge button and turning thenipple tube. Counterclockwise for more air,clockwise for less air. Adjust the regulator sothat a hiss is heard while holding the spannerwrench against the purge button, but the hissingstops when the spanner wrench is removed.

6) Tighten the adjustment lock nut on the nippletube. Use a back up wrench on the main tubewhen tightening to prevent it from spinning.

7) Depress the purge button a couple of times.The mask should not free flow but it should havea good purge.

8) Loosen all the straps on the Spider and holdthe mask on your face. Take a couple of goodbreaths. Breathing slow and soft at first then hardand fast. The regulator should be operating withthe minimal amount of breathing resistance andno free flowing. Any type of an air flow "hiss"should be able to be adjusted out by using theadjustment knob. If the adjustment knob is ad-justed all the way in and the regulator still hisses,readjust the regulator (step 5)

Use the spanner wrench to depress the purge button whileturning the nipple to adjust the regulator.

36



5.8 LENS REPLACEMENTTools required:Dow DC-111 or similar silicone grease7/64" Allen head wrench, flat blade screwdriver,torque screwdriver.

5.8.1 Lens Removal

1) Use a 7/64" Allen head wrench to remove thetwo screws and washers from the sides of thelens clamp. Remove the Nylon lock nuts if theyare loose in the frame.

Install the nuts in the upper lens clamp part of theframe, carefully using needle nose pliers ifneeded. Be sure they are positioned properly andsecurely. Do not squeeze them too tightly or youmay damage the plastic shelf where they seat.

2) Place a bead (approximately 1/8 inch diam-eter) of Dow DC-111 Lubricant or similar sili-cone grease across the entire top lens groove ofthe main mask seal. It should start at approxi-mately 3/4 inch below the top lens clamp cornersand go to the same spot on the opposite side.

3) With the word TEMPERED facing out, holdthe lens up slightly at an angle and begin toinstall the right side of the lens rim into the

EXO Lens Area Diagram

2) Remove the screw and washer from the frontof the lens clamp in the nose area.

3) Separate the lens clamp from the mask frameand mask seal.

4) Carefully remove the old lens from the maskseal by sliding the lens down enough to clear thetop of the lens clamp (which is part of the frame).Remove any silicone from the rubber channel inthe mask seal.

5.8.2 Lens Installation

1) The top lens clamp (which is part of theframe) has flats that will hold the Nyloc lock nutsin place. If the locking feature of this nut is wornout or no longer works, these nuts must bereplaced. DO NOT use any chemical lockingliquids anywhere on the mask. These chemi-cals can attack and damage the mask framematerial.

37



channel of the rubber on the mask seal. Makesure that the mask seal is seated in the maskframe correctly. Start the lens slightly below thetop lens clamp for clearance when installing.Push the lens to the side far enough to make theplastic clamp flex slightly outward allowing thelens to be fitted into place on the other side.

4) Lower the left side of the lens towards theopposite side of the mask rubber and clamp. Justbefore they meet, grab the edge of the rubberchannel and pull it up slightly above the outeredge of the upper lens clamp and press the lensinto the rubber channel and then into the upperlens clamp.

5) Push the lens up and into the rubber channelof the mask seal and top of the upper lens clamp.Hold the lens in position and fit the bottomchannel of the rubber mask seal on the bottomedge of the lens.

Install the right side of the lens rim into the channel of therubber on the mask seal.

Adjust the seal around the bottom of the lens.

Apply silicone grease to the mask seal.

6) Once the lens is properly seated in the maskseal and upper lens clamp, install the lower lensclamp. Place the two ends of the bottom of theclamp onto the outside of the rubber channel tohold the rubber in position. Work the clamp ontothe mask starting at the nose. Make sure therubber is seated evenly onto the lens rim and intothe lens clamp.

7) Push up on the area under the nose screw toalign the nose screw hole in the lens clamp withthe hole in the rubber and the thread insert in theplastic rim on the lens. Insert the slotted screwand the washer here and tighten only about 3 or4 turns. Do not snug or finish tightening thescrew at this time!

38



8) Pull up on the lower lens clamp and install theAllen head screws through the clamp until theythread into the nuts in the upper lens clamp partof the frame. Lightly tighten these screws, alter-nately tightening from side to side so the clampis drawn up evenly, but do not tighten all theway.

9) Finish tightening the nose screw using an inchpound torque screwdriver set at 6 inch pounds.

10) Finish tightening the Allen head clampscrews. Use a flat blade screwdriver very gentlyif needed to keep the rubber from pinchingbetween the two clamps. Tighten the clampsuntil they bottom against each other. Do notover tighten.

CAUTION: DO NOT OVER TIGHTENTHE LENS MOUNT SCREWS. Over tight-ening can cause damage to both thelower lens clamp and the upper clamp/frame requiring replacement.

11) Check the inside top of the glass where itmeets the rubber and make sure everything isproperly seated. Check both sides of the lens andseal. If any excess silicon grease has squeezedout, remove it.

Check the seating of the mask seal and lens clamps on theinside of the mask.

Use a flat blade screwdriver to keep the mask seal frompinching as the lens clamp is tightened.

5.9 BUCKLE REPLACEMENT

Note: The "T" Nuts are made with a special onetime thread locking feature. If the buckles are tobe removed the "T" Nuts must be replaced.

Note: By shortening the short leg of the 1/8"Allen wrench (see photo) this job is made mucheasier.

5.9.1 Buckle Removal

1) Remove the spider (Head harness)

2) Use a 3/16" Allen wrench to remove the "T"nuts and a 1/8" Allen wrench to remove thescrews that hold the buckles and buckle capson.

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5.9.2 Buckle Installation

CAUTION: If the “T” nuts are notproperly installed there is the possibil-ity the screw will become loose and fallout. This will result in the loss of an en-tire buckle assembly and could causethe mask to flood if enough buckles arelost. Become familiar with the way the wash-ers should fit to the “T” nuts. When prop-erly installed the washers will fit around theminor diameter of the “T” nut when prop-erly in place. The washer MUST NOT be cap-tured between the head of the Allen screw andthe end of the “T” nut when tightened.

1) Install all the washers onto the screws withthe sharp side of the washer towards the head ofthe screw.

2) Fit the buckles up into the bottom side of thebuckle caps. Insure that the buckles are facingthe right way. The folded piece of the buckle

assembly with the mounting hole through it hasa loop in it. This loop should fit into the space onthe bottom side of the buckle caps.

3) Fit the “T” nuts through the top sides of thebuckle cap and through the mounting hole in thebuckle.

4) Apply a small amount of silicone grease to thehole on the tab of the mask seal.

EXO Buckle Diagram.

Lightly lubricate the screw hope on the spider tab.

40



5) Place an Allen screw with a washer on it ontothe shortened leg of the 1/8" Allen wrench.

6) Take one entire assembly of “T” nut, bucklecap, and buckle and press the end of the “T” nutthrough the hole on the back side of one of thetabs on the mask seal, then through the maskframe. Insert the 3/16" Allen wrench in the “T”nut and hold the assembly in place on the frame.

7) Take the Allen screw with a washer on it onthe 1/8" Allen wrench and hold it up against theback side of the “T” nut. Turning the 3/16" Allenwrench and the “T” nut, thread the screw into the"T" nut. Tighten the screw and "T" nut. Onceagain make sure that the washer is correctlypositioned on the "T" nut and that it is notcaptured.

8) Repeat steps 3 thru 7 for all the buckleassemblies.

5.10 REPLACING THE FACE SEAL OR FRAME

The Face seal should be inspected prior to ev-ery dive to check for punctures, tears or signs ofcracking. A torn or cracked face seal may causethe mask to free flow and/or flood. If the faceseal is damaged, it must be replaced. This canbe a difficult procedure. It is recommended thatthis procedure be done by a factory trainedKMDSI dealer. If you are going to attempt thisprocedure, read and understand all previoussections of this chapter before you start. TheEXO Tool Kit, Deluxe KMDSI Part #325-650is required to do this procedure.

Tools Required:3/16 inch Allen wrench, 1/8 inch Allen wrench,EXO Tool Kit, Deluxe

5.10.1 Face Seal Removal

1) If you are using communications, removethe communications module, microphone andearphones. See chapter 6.

Insert the screw through the mask frame.

Use a 3/16" allen wrench to tighten the "T" nuts.

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2) Release the spider from the buckles and re-move.

3) Remove the regulator assembly. See section 5.6.1

3) Remove the lens. See section 5.8.1.

4) Remove the buckles and buckle caps. See section 5.9.1.

5) Separate the mask seal from the mask frame.

5.10.2 Face Seal Installation

1) Put the mask seal into the frame. Seat thelens seal area of the mask seal into the upperlens clamp part of the frame. Seat the regulatorand comm module areas of the mask seal in thecorrect spots on the frame.

2) Install the regulator assembly. See section 5.6.2.

3) Install the lens. See section 5.8.2.

4) Install the buckles and spider. See section 5.2.

5) Install the communications module. See chapter 6.

5.11. MANIFOLD BLOCK MAINTENANCE

5.11.1 Daily- A daily pre-dive inspection shouldbe done prior to using the Manifold Block. Care-fully inspect the assembly for any sign of dam-age or worn components.

Tools: open end wrenches, 1", 11/16", 9/16", 5/8" and a 5/16 Allen wrench.

1) Check to insure all the port plugs are installedand are tight.

2) Check to insure the auxiliary gas supply whipis installed and tight, on the auxiliary valve

3) Using a 5/8" open-end wrench, check to en-sure the packing nut (4) on the auxiliary valve(9) is snug. Note: do not over tighten. The valvehandle should turn freely. Check to ensure thepacking nut does not turn -when a light force isapplied with the wrench.

4) Insure the non-return valve (I4) and umbili-cal adapter are securely in place.

5) Test the one way valve (14) by sucking onthe inlet fitting ( I 2) with your lips. If any air isdrawn through the valves the valve must be re-built or replaced.

5.11.2 Post Dive Procedures.

Daily post dive Maintenance of the manifoldblock requires a brushing with a solution of mildsoapy water and a thorough rinsing with freshwater. If hoses have been removed, insure portplugs have been installed and the umbilical con-nection has been capped or bagged.

5.11.3 Annual Overhaul of the

KMDSI ManifoldBlock

42



Manifold Block Assembly.

The KMDSI manifold block should be rebuilton an annual basis, or when damage or corro-sion is suspected or found.

Tools required: Table vise, 1 "open end wrench(2ea), l l/16", 5/8", and 9/16" open end wrenches,large flat blade screwdriver, 5/16 Allen wrench,0-300 in Ibs. Torque wrench, Soft nylon toothbrush, brass O-ring pick and a solution of 50/5O white vinegar and water.

Parts required:Manifold Repair Kit KMDSI PN 325-095

5.11.3.1 Disassembly of manifold block

1) Remove the two flat head screws from themanifold backing plate, and remove the plate.

2) Remove all hoses and port plugs. Removethe O-ring from each plug and place the plugsin a solution of 50/5O white vinegar and water.

3) Using a soft jaw vise or a rag wrapped aroundthe manifold block to keep from marring the fin-ish, remove the one way valve from the mani-fold block using the 1" wrench.NOTE: The one way valve must be removedfrom the manifold block before the auxiliaryvalve.

4) Using the 9/16 open-end wrench, loosen andremove the auxiliary valve from the manifoldblock.

5) Place the manifold block body in a solutionof vinegar and water, and allow to soak whilethe other components are being disassembled.Using the I " wrench and the 9/16 wrench, loosenand remove the umbilical adapter fitting. Placeit in the vinegar solution.

6) Carefully clean the manifold block body with

a nylon toothbrush and vinegar solution. Re-move all traces of old lubricants, dirt and corro-sion, rinse with fresh water and blow dry withcompressed air or allow to air dry. Using thenylon brush, clean the manifold plate and um-bilical adapter. Take special care to remove allthe old Teflon tape from the threads of the um-bilical adapter. Air or blow dry. Inspect allthreaded ports for any damage.

5.11.3.2 Disassembly and cleaning of the oneway valve.

Tools Required:Soft Jaw Vice1 inch Open End Wrench Attachmenton Torque Wrench(If no vise is available use a backup 1 inch openend wrench)

The correct assembly order for the one way valve

123456789

1 O-Ring2 Body3 Spring4 Poppet

5 O-Ring6 O-Ring7 Wiper8 Seat9 Adapter

To disassemble and inspect the one way valveassembly:

1) Use two wrenches or hold the hex part of thebody (2) in a soft jaw vise while removing theseat (8) with a wrench.

43



2) Insert the new spring (3) into the valve body(2), followed by the poppet.

3) Next, install the new O-ring (6) and new wiper(7) on the seat (8). Thread the seat into the valvebody .

4) Tighten the seat to 240 inch lbs. with a torquewrench while holding the body in a soft jaw viceor with another wrench.

5) Re-tape the pipe threads on the umbilicaladapter fitting with Teflon tape, starting twothreads back. One and one half wraps is all thatis required. Reinstall the umbilical adapter andsecurely tighten.

NOTE: The one way valve must be installed inthe manifold block after the auxiliary valve.

6. Lightly lubricate a new O-ring (1), and in-stall onto the one way valve body. Reinstall theone way valve into the manifold block only af-ter the auxiliary valve has been installed. Torqueto 240 inch Ibs.

5.11.3.4 Disassembly of the Auxiliary Valve.

Tools Required:11/16 inch Open End Attachment on TorqueWrench1 inch Open End Attachment on Torque Wrench3/8 inch Slotted Flat Blade Screwdriver8 inch Adjustable Wrench

1) To remove the auxiliary valve body from themanifold block the one way valve assembly mustfirst be removed.

NOTE: If only the auxiliary valve is being ser-viced, it does not have to be removed from themanifold block to be rebuilt.

2) Remove the lock nut (1), spring (2), and knob(3).

CAUTION: Do not use pliers on themain body of the one way valve. You maydamage the valve if pliers are used.

As the seat is removed, the wiper (7) and the O-ring (6) slide out in place in a groove on theseat. The poppet (4) and the poppet O-ring (5)usually come out in the seat being followed bythe spring (3). The only functional part remain-ing in the valve body is a non-moving, pressed-in cage. The function of the cage is to preventthe poppet O-ring from blowing out of placeduring high flows.

2) Inspect the body interior for foreign matterof any type and clean, if necessary.

3) 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 avail-able for replacement parts. (KMDSI Part #525-330)

4) 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 toprevent foreign materials from sticking to thesecomponents.

5) Inspect the spring and clean or replace if nec-essary.

5.11.3.3 Reassembly of the One Way Valve

1) Slide the new O-ring (5) over the poppet (4).

44



3) Undo the packing nut (4). When the packingnut is free of the threads of the auxiliary valvebody (8), back out the stem (7) until it is free ofthe auxiliary valve body.

4) Remove the packing nut, packing (5), andwasher (6) from the stem (7).

5.11.3.5 Cleaning and Lubricating the Auxiliary Valve.

1) Clean all the metal parts in a 50/50 dilute so-lution of white vinegar/water. Rinse with freshwater.

2) Inspect the packing and washer for wear andreplace if necessary.

3) Inspect the stem seat for unevenness or wearand replace if necessary. It must also be replacedif the stem is bent.

4) Check the seat in the auxiliary valve body forwear or unevenness. Replace the body if neces-sary.

5.11.3.6 Reassembly of Auxiliary Valve

Tools Required:11/16 inch Open End &1 inch Open End At-tachments on Torque Wrench3/8 inch Slotted Flat Blade ScrewdriverSoft jaw vice, Teflon tape

1) With the exception of the tapered pipe threadend of the auxiliary valve body (19), lubricateall components with a light coating of siliconegrease.

2) Place the new Teflon washer (6) and newpacking (5) on the stem. NOTE: There are twodifferent packings and washers supplied in thekit, for rebuilding both the older style and thenewer high flow auxiliary valve. Match theremoved packing and washer to the new onessupplied and discard the others.

3) Holding these components in place on thestem, screw the stem into the auxiliary valvebody. Inspect the packing and washer

1

2

3

4

56

78

Auxiliary Valve Components

45



4) Rotate the stem until it is seated all the wayin.

5) Thread the packing nut onto the body. Runthe nut in and tighten slightly with a wrench.

6) Place the knob onto the stem and rotate thestem all the way out, then back again. The rota-tion must be smooth. If “hard spots” or uneven-ness are felt during the rotation, the stem maybe bent and could need replacement.

7) Tighten the packing nut with a wrench untilmoderate resistance is felt when turning theknob.

8) Place the spring and locknut onto the stem,securing the knob.

9) Tighten the locknut until the screwdrivermakes contact with the stem. The assembly isnow complete and ready for testing.

10) Test the valve by attaching it to an auxiliaryair supply source. There must be no leakage ofgas past the stem or through the packing nut.Turn on the bailout bottle and leave the supplyon for several hours. There must be no drop inpressure in the system if the valve is operatingproperly.

11) Apply Teflon tape to the pipe threads start-ing two threads back. Only one and one halfwraps is all that is necessary.

DANGER: Take care not to allow any

pieces of Teflon tape to enter the sideblock. If these pieces of tape enter thedemand regulator assembly and/or de-fogger valve they may block the flow ofair to the diver. This could lead to deathfrom suffocation.

12) Reinstall the auxiliary valve into the mani-fold block and tighten. Insure the valve body isoriented in the proper position so that the oneway valve can be reinstalled.

5.11.3.7 Reassembly of the Manifold Block Assembly.

1) Lightly lubricate new O-rings and install onall port plugs.

2) Ensure that all supply hoses have beenchecked for damage and corrosion and that allhose's have new O-rings which have been lightlylubricated

3) Reinstall the backing plate. Install the screwsand washers.

4) Reinstall all hoses and perform a test of thesystem. Test the auxiliary valve by attaching itto a bail out cylinder and first stage regulatorwith an intermediate air source no greater than240 psi. There should be no leakage of air whenthe assembly is immersed in a tub of water. Theone way valve can also be tested at the sametime. After the water test for leaks, while thesystem is still under pressure, blow dry the inletto the one way valve and then depressurize thesystem.

46



N O T E S

47



CHAPTER 6Communications

The EXO may be ordered either with no commsor with one of three different communicationsmodules. They are: Binding Posts for bare wireconnection, Waterproof Connectors for hardwire communications, and Wireless communi-cations.

In surface supplied diving the most commonlyused types of connectors are the binding postsand the waterproof connectors. Waterproof con-nectors provide better communications. In addi-tion, if you are diving in salt water, waterproofconnectors will extend the life of the communi-cations wire in your umbilical.

6.1 BARE WIRE BINDING POSTS

To connect bare wires to binding posts, be sureyou have a sufficient length of clean, bare wireexposed. If the wire is covered with corrosionclean it until the shiny wire is exposed or cut itback and expose new wire.

1) Twist the wire strands in each individual wireuntil they are wound tightly together. Coat thesewith a thin coat of solder to prevent fraying.

2) Unscrew each of the binding post nuts untilthe hole in the shaft of the post is exposed.

3) Insert one soldered wire into each of the holesin the binding posts. The wires should stick outof the hole of each post, but should not toucheach other. If the wires touch, you will create a“short” and there will be no communicationsbetween the diver’s mask and the top side com-munication box.

4) Tighten each of the binding post nuts untilsnug. Do not overtighten.

5) Test the communications system and insurethat it is in proper working order.

6.2 WATERPROOF CONNECTOR (WPC)

Waterproof connectors are a little more expen-sive than bare wire posts, but they provide bettercommunications, the possibility of a 4 wiresystem, and will extend the life of the diver’sumbilical communications wire. Salt water en-tering the bare wire system will lead to corrosionof the wires and possible failure of the system.

Coat with a thin coat of solder to prevent fraying.

48



Waterproof connectors are rugged but require abit more care in handling than binding postconnectors. If you are careless in handling awaterproof connector you may cause it to failand they can not be repaired. Most waterproofconnector manufacturers recommend that youlubricate the connections using silicone grease.

2) Press the two connectors together until youhear a distinct “pop”, which is the air escapingfrom between the two connectors, creating aseal.

3) Tape the two connectors with a bit of electri-cal tape to prevent them from pulling apart.

4) Test the communications system and insurethat it is in proper working order.

6.3 WIRELESS COMMUNICATIONSThe EXO mask may also be used with wirelesscommunications. There are several manufac-tures of these units, OTS (Ocean TechnologySystems) andDiveComm, just to name a few.Read and follow the manufacturers instructionsfor these units.

Wireless systems are usually only employed byfree swimming SCUBA divers. Wireless sys-tems allow the diver to swim unrestricted by anylines or tethers. However, if you are using theEXO in the surface supplied mode it is usuallymore effective and reliable to use a hard wiresystem.

Wireless systems are used in many differenttypes of diving. Some examples include searchand rescue, research diving, and SCUBA in-struction. With a wireless system it is possible tocommunicate both diver-to-diver and/or diver-to-surface.

EXO STANDARD or BR Module Assembly WithWaterproof Connector

1) To connect the male and female portions ofthe waterproof connectors, align the key on themale connector with the yellow mark on thefemale connector.

Align the key on the male connector with theyellow mark on the female connector. The EXO mask with wireless communications.

49



The communications system should always betested and any problems solved or adjustmentsmade prior to the diver entering the water. Pro-cedures may vary between the makers of the topside communication boxes. Follow the manu-facturers instructions on how to test these units.

6.4 REMOVING THE COMMUNICA-TIONS MODULE

After each days diving, the entire mask commu-nications system should be removed, cleaned,and allowed to dry.

1) First remove the communications mountingring by unscrewing it.

CAUTION: Do not apply any pres-sure to either the penetrator, or the com-munications posts, for removal. Thiscould possibly damage the unit.

2) Reach inside each earphone pocket, grasp theearphone and remove it.

CAUTION: Do not remove the ear-phones by pulling on the wires. This maydamage their interior connections.

WARNING: The waterproof casefor your wireless communications unitshould only be attached to your scubabackpack, never to your weight belt. Inthe event your belt must be dropped thebelt must have a clear drop path andmust not be connected to any other pieceof gear. If this procedure is not followedthe weight belt and wireless electronicscase will be attached to the mask by theconnecting wire.

The communications system should always be tested priorto the diver entering the water.

Remove the earphone assembly.

3) In the EXO Standard or Balanced remove themicrophone from the oral nasal. Once again donot pull on the wire as this can damage theconnection.

50



4) The entire communications assembly cannow be separated from the mask. The moduleshould be pushed to the inside of the mask byapplying pressure to the flat angle area on theexterior of the comm module.

5) Remove the outer earphone covers, and onthe EXO Original the microphone cup, andallow all the parts to dry.

6.5 INSTALLING THE COMMUNICA-TIONS MODULE

If you are installing communications into a maskthat did not originally come with communica-tions, the back side of the microphone cup on theoral nasal may need to be trimmed out. If it is thenewer version, simply remove the plastic plug.

1) Insure that the mask seal is correctly seated inthe frame. This is very important as the maskseal also acts as the seal for the communicationsmodule.

2) Reassemble the earphone covers and themicrophone cup (EXO Original).

Remove the outer earphone covers and allowall the parts to dry.

3) If the comm module is equipped with awaterproof connector, insert the waterproof con-nector back through the mask seal and framefrom the inside of the mask

4) Work the comm module into the mask sealfrom the inside until it is properly positioned andseated. On the EXO original, make sure themicrophone cup is positioned correctly.

Make sure the microphone cup in the EXO Originalis positioned correctly.

5) Screw the comm module mount nut back ontothe comm module and tighten.

6) Insert the earphones in their pockets. Using apump spray type of silicone, a light coat on theoutside of the earphone covers helps the ear-phone assembly to slide into the pocket easier.

CAUTION: Avoid spraying cannedsilicone spray on any of the plastic partsof the mask. Certain chemicals used topropel silicone spray from the can maydamage the plastic components of themask. Use silicone in a bottle with amanual pump or a very light applicationof silicone grease.

7) Tuck any excess wires behind the edge of themask seal.

51



8) Mount the microphone back into the oralnasal (EXO Standard or BR).

9) Test to insure that the communications mod-ule is in proper working order.

10) Masks not using communications systemsshould be fitted with an oral nasal microphonecup plug. KMDSI oral nasal plug, part # 320-001is available for this purpose.

6.6 EARPHONE AND/OR MICROPHONEREMOVAL

1) Remove the communications assemblyfrom the mask.

2) Remove the comm module cover (EXOStandard or EXO BR).

3) Using a small flat blade screwdriver,carefully scrape out the waterproof coating inthe slots of the screws in the comm moduleand remove the screws and washers. Takenote of where all the wires are connected, itwill help when reassembling the unit.

4) Carefully remove the wires from the mod-ule.

6.7 EARPHONE AND/OR MICROPHONEINSTALLATION

1) Test the assembly, earphone or microphone,to insure that your components are functioningproperly before installation into the commmodule.

2) Insert the wires into the comm module oneat a time in the correct order (see above).

3) Use the correct wiring diagram at the end ofthis chapter for your communications set up toreconnect the wires into the comm moduleusing the screws and washers.

4) Test the communication assembly.

5) Once the comm assembly has been testedand is in working order, paint a light coat ofRTV silicone sealant onto the screws, wash-ers, and terminals to waterproof them.

6) Reinstall the comm module cover (EXOStandard or EXO BR).

6.8 REMOVING THE WATERPROOFCONNECTOR (WPC)


2) Remove the comm module cover (EXOStandard or EXO BR).

3) Remove the earphones and microphoneconnections from the comm module.

4) The WPC mount nut on the inside of thecomm module should be held so that it won'tturn. Use a 3/4" open end wrench on theexterior WPC packing and unscrew the WPCassembly from the comm module.

5) Remove the WPC mount nut from insidethe comm module.

Microphone Wire

Left Earphone Wire (Long) Right Earphone

Wire (Short)

Insert the wires into the comm module one at a time inthe correct order

52



6.9 INSTALLING THE WATERPROOFCONNECTOR (WPC)

1) Put a small bead of RTV silicone sealantaround the top part of the threads on the WPCpacking where it rests against the commmodule to form a seal between the WPC andthe comm module.

2) Put the WPC mount nut in the commmodule and hold it up against the hole in thecomm module.

3) Feed the wires from the WPC through thehole in the module and through WPC mountnut. Screw the WPC assembly into the commmodule and tighten. Clean any excess RTVfrom around the WPC packing.

4) Feed the earphone and microphone wiresinto the comm module. Make sure they are inthe right order. (Fig. 6.)

5) Follow the appropriate wiring diagram andreconnect the wires.


7) Once the comm assembly has been testedand is in working order, paint a light coat ofRTV silicone sealant onto the screws, washers,and terminals to waterproof them.


6.10 REMOVING THE BINDING POSTS


2) Remove the comm module cover.

3) Remove the earphones and microphonefrom the comm module. Take note of where

all the wires are connected. This will helpwhen reassembling the unit.

4) Use a metal pick or a small stiff piece ofwire and insert it through the wire connectionhole in the binding post. This will help youhold on the post and either spin it or keep itfrom spinning. Also, use a 3/8" open endwrench on the binding post mounting nuts onthe inside of the module and unscrew thebinding posts.

5) Remove the nuts, washers, and wire har-nesses from the inside of the comm module.Take note of where all the wires are con-nected, it will help when reassembling theunit.

6.11 INSTALLING THE BINDING POSTS

1) Put a bead of RTV silicone sealant aroundthe bottom of the threads and on the bottom ofthe binding post body.

2) Insert the binding post into one of the holesin the comm module.

3) Put one end of the wire harness on the endof the post, followed by the washer, and nut.Tighten the binding post into the commmodule. Repeat for the other post.

Use a metal pick or a small stiff piece of wire insertedin the binding post to keep it from spinning.

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4) Feed the earphone and microphone wiresinto the comm module. Make sure they are inthe right order. Refer to the Installing theEarphone and Microphone section of thischapter.

5) Follow the appropriate wiring diagram toreconnect the wires.


7) Once the comm assembly has been testedand is in working order, paint a light coat ofRTV silicone sealant onto the screws, wash-ers, and terminals to waterproof them.


6.12 WATERPROOF CONNECTOR(WPC) ASSEMBLY REBUILD

1) Remove the waterproof connector (WPC)assembly from the comm module.

2) Cut off the terminals or "sweat " them offwith a soldering iron if you are going to reusethem.

3) Unscrew the packing gland from the pigtailnut. Take off the packing gland, rubber seal,packing washer and pigtail nut. Note theposition of the rubber seal and the packingwasher and the directions that they face.

Waterproof Connector Assembly

4) Discard the old WPC.

5) On new WPC's the black casing may needto be stripped back 1 1/4" from the end of thewires. The tips of the wires usually comealready stripped and dipped in solder. If not,strip the end of the wires 1/4" and solder theends to prevent fraying.

6) Lightly grease 2 " of the black casing withsilicone grease to help slide the pigtail nut on.Slide the pigtail nut on, making sure it faces inthe correct direction.

7) Position the packing washer 2 1/4" from theend of the wires and facing in the correctdirection. Put the rubber seal on also facing inthe correct direction and slide it up against thepacking washer.

8) Slide the packing gland on up against therubber seal, making sure it is facing in thecorrect direction. Try not to move the posi-tion of the packing washer.

9) Screw the packing glands and pigtail nuttogether and tighten.

10) Solder terminals on to the end of thewires.

11) Test WPC assembly with a multimeter ifpossible to insure that all connections aregood. Reinstall WPC assembly in commmodule. See 6.8

Waterproof ConnectorPigtail Nut

Packing Washer

Rubber Seal

Packing Gland

Mount Nut

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White Wires, EarphonesMicrophone

Black Wires, EarphonesMicrophone

2 Pin Waterproof Connector

4 Pin Waterproof Connector

White Microphone Wire

Black Microphone Wire

White Earphone Wires

Black Earphone Wires

6.13 WATERPROOF CONNECTOR (WPC)PIN DIAGRAMS

The view in these diagrams is looking straightat the pins on the WPC. The large pin is at thetop.

6.14 POST DIVE MAINTENANCE

If your mask is equipped with any type of com-munications, post dive maintenance on the maskand communications module must be done af-ter each days dive. The post dive procedures mayvary between manufacturers, depending onwhich communication module you are using.Follow the manufacturers instructions on postdive maintenance. The following is the recom-mended post dive maintenance procedures forthe KMDSI communications modules.

1) Remove the communications from the mask.

2) Lightly rinse the assembly with fresh cleanwater. Do not immerse the entire assembly un-der water and try to keep the water out of theearphone covers and from under the modulecover. The microphone can get wet.

3) Dry the assembly off. Open the earphone cov-ers and take the module cover off and let every-thing dry on the inside.

4) Once everything is dry, reassemble the ear-phone covers and reinstall the module cover.

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Screws and Washers

Wire HarnessWhite Earphone WiresWhite Microphone Wire

Wire HarnessBlack Earphone WiresBlack Microphone Wire

Binding Post Wire Harness

Binding Post Wire Harness

Binding Posts

2 Pin 2 Wire, Waterproof Connector (WPC)

Screws and Washers

2 Pin 2 Wire WPC Assembly

White WPC WireWhite Earphone WiresWhite Microphone Wire

Black WPC WireBlack Earphone WiresBlack Microphone Wire

4 Pin 4 Wire, Waterproof Connector (WPC )

Green WPC WireWhite Earphone Wires

Black WPC WireBlack Earphone Wires

White WPC WireWhite Microphone Wire

Red WPC WireBlack Microphone Wire

4 Pin 4 Wire WPC Assembly

Communications Module Assembly Wiring Diagrams

Documents

Operations & Maintenance Manual for the EXO Original and ... · Document # 020905002 Kirby Morgan Dive Systems, Inc. (KMDSI) is the same corporation (with only a name change) that