Head Cushion, Head Cushion Foam Spacer (HCFS) and Chin Cushion
Contents
HDCSH-1 1.1 Head Cushion
HDCSH-1 1.1.1 Head Cushion Removal
HDCSH-1 1.1.2 Head Cushion Test Fit
HDCSH-2 1.1.3StuffingtheHeadCushionBag
HDCSH-3 1.2 Head Cushion Foam Trimming
HDCSH-3 1.2.1AddingEarphoneHolesto the Head Cushion
HDCSH-3 1.3 Head Cushion Foam Spacer (HCFS)
HDCSH-5 1.3.1 Installation of Head CushionFoamSpacer(HCFS)
HDCSH-6 1.3.2StuffingtheHeadCushionFoamSpacer(HCFS)
HDCSH-6 1.4 Chin Cushion
HDCSH-6 1.4.1StuffingtheChinCushion
HDCSH-7 1.5 Clean and Inspect
1.1 Head Cushion
B WARNINGA loose fitting head cushion will cause poor oral nasal mask fit resulting in CO2 buildup in the helmet. This condi-tion could lead to a build up in CO2 (Hypercapnia), possibly resulting in unconsciousness, serious injury or death.
The fit of the head cushion is critical to bothcomfortandsafety.Ingeneraltheheadcushionshouldbesnugfittingandhelpholdthehelmetto your head. The head cushion should also beadjustedsoitassistsintheproperfitoftheoralnasalmasktotheface.
The fit of the helmet is primarily determinedbythelayersofopencellfoamthatfilltheheadcushionbag.
B WARNINGNever dive with a Kirby Morgan hel-met without a properly functioning oral nasal mask. Without an oral na-sal mask, dangerous levels of carbon dioxide may accumulate in the helmet. This can lead to unconsciousness and death.
Theheadcushionispartofthehelmetcushion-ing system that includes thehead cushion, theheadcushionfoamspacerandthechincushion.
1.1.1 Head Cushion Removal
The head cushion is fastened into the helmetwithsnaps.Removetheheadcushionbyputtingahandatthebaseofthesnapandgentlysepa-ratingthesnapsoneatatime.
1.1.2 Head Cushion Test Fit
Fit test (follow these instructions if refitting orre-sizingtheheadcushion).
Makesuretheneckpadonthelockingcollarisadjustedcorrectlytothediversnecksizeandalsocheckthefitoftheheadcushionwiththelockingcollarintheclosedposition.
NOTE:Fordiverswithsmallersizedheadsuseoftheheadcushionfoamspacer(HCFS,P/N525-745)mightberequired.ItshouldbenotedthattheChinCushionP/N510-667analsobeusedtosafeguardproperfitofthediversfaceintotheoralnasalmask.
1)Snapchincushion(ifused)andheadcushioninto helmet.
2)Donthehelmetandevaluateifitisthecorrectfitorwillneedtobeadjusted.
©MMXVIIIKirbyMorganDiveSystems,Inc.Allrightsreserved.Document#180503015 HDCSH-1
Head Cushion, Head Cushion Foam Spacer (HCFS) and Chin Cushion Head Cushion
NOTE: If the head moves, the helmet should follow.
1.1.3 Stuffing the Head Cushion Bag
There are a number of ways to stuff the headcushion with foam. Different combinations ofthe provided foam can be set up and foam canbetrimmeddependingondesiredfit.Thebelowstepsareintendedtoonlyaidandguidetheuser.
The components of the head cushion.
NOTE:TheneckpadfoamP/N510-832cangooneithersideofthetopfoamstripsP/N510-830,againsttheneckoragainstthehelmetshell.Theneckpadfoamisasizingtoolandcanberemovedorleftintheheadcushionbagtoensureproperfitandcomfort.
TIP:Firstchooseeithertherightorleftsideoftheheadcushionbagtobeginstuffingthe“eggshell” foam.
The “egg shell” side of the left and right side foams usually faces outward against the helmet shell.
Next insert the top foam, followedby theothersideof“eggshell”foamandfinishwiththewhiteneckfoampad.
HDCSH-2 ©MMXVIIIKirbyMorganDiveSystems,Inc.Allrightsreserved.Document#180503015
Head Cushion Head Cushion, Head Cushion Foam Spacer (HCFS) and Chin Cushion
1.2 Head Cushion Foam TrimmingNOTE: The side “egg shell” foamsdonothaveearholes.Thisisintentional.Earholesmaybecutinifpreferred.Thetipsofthe“eggshell”sidecanbetrimmedoffifthesidefoamsaretootight.
The tips of the “egg shell” side can be trimmed off if the side foams are too tight.
1.2.1 Adding Earphone Holes to the Head Cushion
Using the template for general size and location, mark the desired area for cut out, if required.
Trim the ear hole into the foam using the guide line made from the Ear Hole Template
1.3 Head Cushion Foam Spacer (HCFS)Theheadcushionfoamspacer(HCFS)isasim-ple lengthof foam that isnested into theheadcushion.Thespacerhelpsproperlyposition thetopandbackoftheheadinthehelmetbyusingalargerfoampieceinthelowerneckareawhichhelpspushtheheadforward,andthenoseandmouthintotheoralnasalmask.
©MMXVIIIKirbyMorganDiveSystems,Inc.Allrightsreserved.Document#180503015 HDCSH-3
Head Cushion, Head Cushion Foam Spacer (HCFS) and Chin Cushion Head Cushion Foam Trimming
1) C
ut o
ut te
mpl
ate.
2) M
atch
tem
plat
e to
low
er p
ortio
n of
hea
d cu
shio
n si
de fo
ams.
3) M
ark
hole
usi
ng a
felt
tip p
en.
4) T
rim h
oles
in fo
a m.
NO
TE:
The
hole
loca
tion
and
size
are
pro
vide
d on
ly a
s a
gene
ral r
efer
ence
. The
size
and
loca
tion
can
be c
hang
ed to
su
it th
e in
divi
dual
.
Kirb
y M
orga
n®
Hea
d C
ushi
on S
ide
Foam
(L &
R)
Ear
Hol
e Tri
m T
empl
ate
1"
Ear Hole Trim Template
HDCSH-4 ©MMXVIIIKirbyMorganDiveSystems,Inc.Allrightsreserved.Document#180503015
Head Cushion Foam Trimming Head Cushion, Head Cushion Foam Spacer (HCFS) and Chin Cushion
The components of the head cushion foam spacer (HCFS).
1.3.1 Installation of Head Cushion Foam Spacer (HCFS)
NOTE: In September of 2012 the head cush-ion foamspacer (HCFS)wasupgradedwithanelastic/Velcro®strapatthetopfrontpartoftheHCFSbag.ThisnewfeatureisintendedforusewithheadcushionsP/N510-754,orthe510-521whichhasmatingVelcro®patches.
NOTE:IfusingtheHCFSwithP/N510-682oraP/N510-521withoutaVelcro®patch,theelastic/Velcro® strapcansimplybe foldedover the topfrontportionbetweentheheadcushionandthehelmetshell,oritmaybetrimmedoffifdesired.
1)InstalltheHCFSintothetopinsideportionoftheheadcushion.Wraptheelastic/Velcro®straparound the front top edge and attach onto thematingVelcro®patchinfrontofthehangingloop.
The tag on the HCFS
and sewing seam should
be facing the back against the
head cushion.
Proper installation and alignment of the HCFS in the helmet.
©MMXVIIIKirbyMorganDiveSystems,Inc.Allrightsreserved.Document#180503015 HDCSH-5
Head Cushion, Head Cushion Foam Spacer (HCFS) and Chin Cushion Head Cushion Foam Spacer (HCFS)
Hold the HCFS towards the back of the helmet when donning.
B CAUTIONEnsure that the HCFS is properly po-sitioned against the back of the head/neck and does not get caught between the helmet ring and the neck dam rings when closing the helmet. Failure to do so could result in an improper seal.
1.3.2 Stuffing the Head Cushion Foam Spacer (HCFS)
1)Stufftheneckfoamblockfirst,followedbythetopfoamintotheHCFSbag.ClosetheVelcro®.
NOTE:MatchtheshapeoftheneckfoamblockwiththeshapeoftheHCFSbag.
Match the shape of the foam
block with the shape
of the pocket.
Position sewing seam and tag on back side.
1.4 Chin CushionTheChincushionisfastenedtothehelmetwithtwosnapsandshouldrestonthediverschin.Thechinstrapistightenedontheoutsideofthechincushionastopressthechincushionsnugagainstthediverschin.
The chin strap is tightened on the outside of the chin cushion as to press the chin cushion snug against the divers chin.
1.4.1 Stuffing the Chin Cushion
Matchtheshapeofthechincushionfoamtothechincushionbag.
HDCSH-6 ©MMXVIIIKirbyMorganDiveSystems,Inc.Allrightsreserved.Document#180503015
Chin Cushion Head Cushion, Head Cushion Foam Spacer (HCFS) and Chin Cushion
1.5 Clean and InspectThe cushion foam must be replaced when thefoambeginstocrumble.Loosecushionswillcre-ateasloppyfittothehelmetandcouldcausedis-comfortand/orinjurytothediver.
1)Cleanheadcushionbagusingmildsoapandwater.Rinsethoroughlyandhangdry.
2)InspecttheheadcushionbagtoensuretherearenoripsortearsinthematerialsandthatthesewingandVelcro®orzipperareingoodworkingcondition.Replaceifneeded;orderheadcushionbag,P/N510-722.
©MMXVIIIKirbyMorganDiveSystems,Inc.Allrightsreserved.Document#180503015 HDCSH-7
Head Cushion, Head Cushion Foam Spacer (HCFS) and Chin Cushion Clean and Inspect