A2.1 – Annual Inspection / Overhaul (Sections 1–4)

Equipment
Customer
Valen marina AS
Location
Valen Marina
Producer
Kirby Morgan
Model
28
Build year
2022
Serial no
22161B
Service interval (months)
12
Certificate type
KMB 18/28 BandMask
Equipment
Standard DS.Core equipment section (as implemented in your shared header/equipment pattern).
Regulator Identification
Checklist (Sections 1–4)
1. Hood Assembly
Remove head harness (spider) and inspect for tearing, deterioration, and/or damage. Ensure all five legs are present. Replace if necessary.
Remove the earphones from their pockets in the hood. Remove the hood from the mask. Perform a visual inspection of all components.
Visually inspect the hood for signs of damage and/or deterioration. Replace if necessary.
Remove the top and bottom bands from the hood. Visually inspect all metal parts of the band assembly and band keeper components, including band screws, for damage. Replace if necessary.
2. Mask Assembly
Visually inspect the mask exterior and interior for loose and/or missing fasteners and obvious signs of damage; including cracks, gouges, and/or depressions.
Remove the covers from the earphones. Remove microphone from the oral nasal mask. Inspect and repair/replace as necessary. Perform a complete communications check.
Remove the nose clearing device. Clean and inspect the nose clearing pad and shaft. Replace O-rings.
Remove oral nasal mask and oral nasal valve as an assembly. Remove valve and valve body as an assembly. Clean and inspect mask for damage. Replace valve and reinstall into valve body. Reinstall valve body into mask.
Remove the comfort insert [KMB 18 only]. Clean and inspect the comfort insert and fastening hardware for damage and/or deterioration. Mark N/A for KMB 28.
Remove the bent tube and replace the Teflon® O-ring on the side block end of the bent tube, as well as the O-ring at the demand regulator inlet side of the bent tube. Replace the bent tube if condition requires.
Remove the demand regulator with whisker wings and exhaust main body as a single unit from the mask and set it aside.
Remove the exhaust main body and both whiskers. Completely disassemble the exhaust system, clean, and inspect it. Replace rubber components if required.
Replace the exhaust valves at least annually or whenever they show signs of deterioration, wear, or damage.
Remove the face port retainer, face port and O-ring.
Perform view port insert pull test. Complete and include the Port Insert Test Sheet (A2.1). Replace the view port O-ring. Follow corrective action if inserts fail.
Install top band keeper mount and lower band keeper mount (if removed).
Remove the main exhaust valve cover and replace the main exhaust/dewatering valve. Inspect seating surface for damage and/or contamination.
3. Side Block
Remove, disassemble and overhaul the one-way valve.
Remove, discard, and replace umbilical adapter with a new one.
Remove, disassemble, and overhaul the EGS and steady flow valve components.
4. Demand Regulator
Disassemble the demand regulator. Inspect regulator body interior for corrosion and/or contamination. Clean as necessary.
Clean and inspect all parts. Replace all O-rings and inlet valve seat. Do not reuse single-use parts.
Reassemble the demand regulator.
Ensure the adjustment shaft rotates smoothly and there is no binding.
Install the exhaust main body and attach the whiskers to each side of the view port retainer.
Mount the regulator to the mask.
Install the bent tube. Ensure the Teflon® washer and O-ring have been replaced.
Reinstall oral nasal mask, valve assembly, and nose block device.
Check the regulator for proper operation and fine tune the adjustment if necessary.
Port Insert Test Sheet (A2.1)
Port Insert Test Sheet (A2.1)
Perform view port insert pull test. Complete and include the Port Insert Test Sheet (A2.1) with the certificate record.
Insert 1
Insert 2
Insert 3
Insert 4
Insert 5
Insert 6
Insert 7
Insert 8
Insert 9
Insert 10
Insert 11
Insert 12
Insert 13
Insert 14
Insert 15
Technical Addendum (Sections 1–4) 
Technical Addendum – A2.1 Checklist (Sections 1–4)

This addendum provides a concise technical description of the inspection and maintenance actions referenced in Sections 1–4 of the A2.1 checklist for the Kirby Morgan® KMB 18/28 BandMask®. It is intended as a procedural reference to support the completed checklist and does not replace the KMDSI Modular Operations and Maintenance Manuals.

1. Hood Assembly
The head harness (spider) is removed and inspected for tearing, deterioration, and missing legs. Earphones are removed from hood pockets and the hood is separated from the mask to permit full visual inspection. The hood is inspected for cuts, abrasion, or material breakdown. Top and bottom bands are removed and all metal parts of the band assembly, band keeper components, and band screws are inspected for damage or corrosion. Replace components if condition is not acceptable.

2. Mask Assembly
The mask exterior and interior are inspected for loose/missing fasteners and structural damage (cracks, gouges, deformation). Earphone covers and microphone are removed from the oral nasal mask; components are inspected and a communications check is performed. The nose clearing device is removed; pad and shaft are cleaned/inspected and O-rings are replaced. The oral nasal mask and valve assembly are removed, cleaned and inspected; the valve is replaced and reinstalled correctly. For KMB 18, the comfort insert and fastening hardware are cleaned and inspected (N/A for KMB 28). The bent tube is removed; O-rings at both ends are replaced and the tube is inspected for damage/corrosion/erosion and replaced if integrity is in question. The demand regulator with whisker wings and exhaust main body is removed as an assembly. The exhaust system is fully disassembled, cleaned and inspected; rubber components are replaced if required and exhaust valves are replaced. The face port retainer, face port and O-ring are removed. Perform the view port insert pull test; complete and include the Port Insert Test Sheet (A2.1) with the certificate record. Replace the view port O-ring and follow corrective action if inserts fail. Band keeper mounts are installed if removed. The main exhaust/dewatering valve is replaced and the seating surface is inspected.

3. Side Block
The one-way valve is removed, disassembled, overhauled and reinstalled. The umbilical adapter is removed/discarded and replaced. EGS and steady flow valve components are disassembled and overhauled as required. Removal of the side block itself is not mandatory for annual service unless condition dictates otherwise.

4. Demand Regulator
The demand regulator is disassembled and the regulator body is inspected for corrosion/contamination and cleaned as necessary. Clean and inspect all parts; replace all O-rings and the inlet valve seat and discard any single-use parts. Reassemble and ensure the adjustment shaft rotates smoothly without binding. Install the exhaust main body and attach whiskers correctly. Mount the regulator to the mask, install the bent tube with replaced washer/O-ring, reinstall the oral nasal mask/valve assembly/nose block device, then function-test and fine tune as necessary.
DS Bergen
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