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© Copyright Dive Lab Inc.® All rights reserved. Rev May 27, 2020
Air Train Installation (This procedure is specific to the KM 37/DAVD Helmet Only)
DAVD System
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© Copyright Dive Lab Inc.® All rights reserved. Rev May 27, 2020
2” STUD Part Number: DL-545-016AB-1
AIR TRAIN Part Number: DL-545-016AB
KIT Part Number: DL-545-016AB-NS
DESCRIPTION &
PARTS INDENTIFICATION
DAVD System Air Train Kit: This kit is to be installed in the Kirby Morgan KM 37 Helmet when used with the DAVD System. The standard Kirby Morgan Air Train and side block mounting Stud have to be replaced with these modified helmet components. The original nut, lock washer and alignment screw are the only parts that are re-used in mounting the side block.
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© Copyright Dive Lab Inc.® All rights reserved. Rev May 27, 2020
TOOLS REQUIRED
Two 7/16, one 11/16, and one 7/8 inch Open End Wrenches
11/16 and 7/8 inch Open End Wrench Attachment on Torque Wrench (crowfoot)
1/4 inch Flat Blade Stubby Screwdriver Wooden Wedge 7/16 inch socket attachment Torque screwdriver with flat blade attachment Torque wrench Loctite 222/248
STEP 1: SIDE BLOCK
REMOVAL
Remove the Side Block assembly In Accordance with the Kirby Morgan Modular Manual Chapter 1, pages SB-6 through SB-8 sections 1.1.5, 1.1.6 and 1.1.7.
a) Before reinstalling side block, remove the old stud by using the double nut method.
STEP 2: SIDE BLOCK
ASSEMBLY INSTALLATION
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© Copyright Dive Lab Inc.® All rights reserved. Rev May 27, 2020
Thread both nuts onto the new 2”stud Tighten nuts against each other at the top of the
stud Remove stud but turning only the bottom nut
counter-clockwise Apply Loctite 222/248 to the provided stud and
thread into the side block until hand tight. Tighten stud into side block using the double nut method again by turning only the top nut clockwise to 20-inch pounds. Ensure it aligns correctly in the holes of the shell by dry fitting, before applying RTV silicone sealant
b) Apply a small amount of silicone sealant to the area around the side block where it makes contact with the helmet shell, prior to installation onto the shell. Use Dow Corning® RTV 732 Multi-Purpose sealant or equivalent. Care must be taken to avoid sealant entering the air opening in the side block.
STEP 2: SIDE BLOCK
ASSEMBLY INSTALLATION
(CONTINUED)
APPLY SEALANT
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© Copyright Dive Lab Inc.® All rights reserved. Rev May 27, 2020
b) continued Be sure to remove all excess silicone sealant before it sets up. Acetone can be used to dissolve uncured sealant on Fiberglass and Stainless-Steel helmet shells. If acetone is unavailable, use lint free towel to remove excess.
APPLY SEALANT
(CONTINUED)
APPLY Loctite 222/248
c) Apply Loctite 222/248 to the 1st quarter inch of the threads on the alignment screw and thread the screw through the shell. Lightly tighten into the side block body. A good indication that enough silicone has been applied will be extrusion of the silicone to the outer edges of the side block. Be sure to remove all excess silicone sealant before it sets up.
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© Copyright Dive Lab Inc.® All rights reserved. Rev May 27, 2020
d) Torque the screw to 15-inch pounds. Recheck for excess silicone extrusion and re-clean as necessary.
APPLY SEALANT
OVER SCREW
APPLY Loctite 222/248
(CONTINUED)
e) Apply Dow Corning® RTV 732 Multi-Purpose sealant or equivalent silicone sealant over the counter-sunk alignment screw. Ensure the silicone is flush with the helmet shell.
TIGHTEN THE SCREW
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© Copyright Dive Lab Inc.® All rights reserved. Rev May 27, 2020
f) Install air train over stud. Align the air train with the upper edge of the view port opening in the helmet shell. Note: Air Train may require slight adjustments, easily made by hand, for optimal fit.
INSTALL AIR TRAIN
g) Install the lock washer onto stud. Run the nut down the stud and tighten to the 20-inch pounds. DO NOT OVERTIGHTEN. Recheck torque of the alignment screw to 15-inch pounds.
INSTALL LOCK
WASHER & NUT
If you have any questions regarding this procedure please contact Dive Lab at [email protected] or call at 850-235-2715. END
