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Kirby Morgan 525-769, Installation Manual

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Kirby Morgan 525-769 Installation Manual Download Page 23

© MMXXI Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 210607001 

23

REX® Pod System and Regulator Removal 

Nose Block Device Installation

Installing the 455 Balanced Regulator onto a KM 77

To remove the REX regulator on the KM 77 and replace it with a 455 Balanced Regulator, the REX Pod 
must be removed. The regulator and REX pod can be removed as one unit.

Along with the corresponding equipment manuals, a two part video illustrating this process can be 
viewed at the Kirby Morgan YouTube channel or by locating the 525-769 kit in the Kirby Morgan website.

Parts Included in the 525-769 Kit:

Part #

Description

Qty

100-100

Warranty Card

1

100-097

Manual, KMDH 97

1

100-204

Installation Guide, 455 Regulator Kit

1

505-776

455 Regulator Pod Assembly

1

510-403

Pod Gasket

1

510-747

Oral Nasal Mask

1

520-042

Tie Wrap

3

525-630

Tool Kit, 455 Regulator

1

530-145

Lock Nut

8

555-155

Bent Tube w/O-rings

1

1.1 REX

®

 Pod System and Regulator 

Removal

VIDEO

How To: Conversion Kit, 
455 Regulator for KM 77 | 
Part 1

https://www.youtube.com/
watch?v=RemxBjTTnlM

Tools Required:

•  Regulator Mount Nut Tool P/N 325-640 (in 

Tool Kit P/N 525-768 Included with Helmet)

• 

3/8

" Drive Extension—Minimum 3" in Length

• 

3/8

" Nut Driver or 

3/8

" Open End Wrench

• 

5/32

" Hex Key (Ball End is Helpful)

•  REX

®

 Regulator Adjustment Tools P/N 540-

550 and 540-552 (in Tool Kit P/N 525-768 
Included with Helmet) 
or 2 ea. 

13/16

" Open Ended Wrenches

• 

7/16

" and 

11/16

" Open End Wrenches

•  #1 Phillips Head Screwdriver

•  Slip Joint Pliers and a Cloth

1. Remove the chin strap by removing the screws 
that secure it.

2. Remove the two snap tabs adjacent to the 
swing catch assembly.

Summary of Contents for 525-769

Page 1: ...ved the Dive Lab CR Commercial Rated mark Kirby Morgan SuperLite BandMask Band Mask KMB KMB Band Mask DSI Diving Systems Internation al EXO REX SuperFlow and DECA are all registered trademarks of Kirby Morgan Dive Systems Inc Use of these terms to describe products that are not manufactured by KMDSI is illegal The two dimensional images such as photographs and illustrations of our products are cop...

Page 2: ...ose Block Device Installation 11 1 3 Test the regulator for proper function Installing the 455 Balanced Regulator onto a SL 17C SL 27 KM 37 or KM 57 Helmet 12 1 1 SuperFlow 350 Regulator Removal 12 1 1 1 Bent Tube Removal 13 1 1 2 Nose Block Device Removal 13 1 1 3 Oral Nasal Mask and Microphone Removal 13 1 1 4 SuperFlow 350 Removal from Helmet Mask 14 1 2 455 Balanced Regulator Installation 14 1...

Page 3: ...llation 22 1 3 Test the regulator for proper function Installing the 455 Balanced Regulator onto a KM 77 23 1 1 REX Pod System and Regulator Removal 25 1 2 455 Balanced Regulator Installation 25 1 2 1 Regulator Mount Pod 350 Installation 26 1 2 2 455 Balanced Regulator Installation 27 1 2 3 Exhaust System Installation 28 1 2 4 Bent Tube Assembly Installation 30 1 2 5 Oral Nasal Mask and Microphone...

Page 4: ...ill not accept the 455 balanced regulator 1 1 CE Certification The helmet has been tested and conforms to the performance requirements as set forth in An nex II of Regulation EU 2016 425 and as far as applicable the EN15333 1 class B It is fully CE marked with the 455 balanced demand regulator and oral nasals P N 510 690 and P N 510 747 NOTE The sticker CE mark inside the helmet or BandMask regard...

Page 5: ...the shell of the helmet Modify or counterfeit the data report ed on the mark B CAUTION The mark must be visible and legible throughout the life of the PPE If the mark deteriorates or is not legible the user should contact the manufacturer 1 1 2 Notified Body The Notified Body is Eurofins Product Testing Italy Srl Address Via Courgné 21 10156 Torino ITALY Identification number 0477 ...

Page 6: ...p Joint Pliers and a cloth 1 1 1 Bent Tube Removal 1 Always start removal at the side block end Loosen the tube with the 11 16 inch wrench The free swiveling mount nut on this end of the bent tube can be unthreaded completely and can slide down the tube Always start removal at the side block end 2 Loosen the lower bent tube nut by using the two 7 8 inch wrenches Place one wrench on the bent tube m...

Page 7: ...oral nasal mask 1 1 3 Oral Nasal Mask and Microphone Removal 1 Verify that the nose block device is removed from the helmet 2 Push the microphone out of the oral nasal mask 3 Pull the oral nasal mask off the regulator mount nut It is held on by a snap fit 1 1 4 SuperFlow 350 Removal from Helmet Mask 1 Verify that the bent tube has been removed from the helmet 2 Remove the screws that secure the wh...

Page 8: ...e final alignment of the regulator may have variation from unit to unit and this in no way will affect the function and or performance of the finished 455 regulator EXHAUST SYSTEM NOTE Each Quad and Tri Valve exhaust assembly can be removed and replaced onto the exhaust flange of the regulator as a complete unit If assembled using the indi vidual components special attention is required to ensure ...

Page 9: ... contaminants and damage Use a tooth brush to clean threads as needed Lightly lubricate the regulator mounting tube threads and the sealing O ring with Christo Lube 4 Install the sealing O ring then thread the regulator mount nut onto the regulator finger tight ONLY 5 Ensure that the Teflon O ring is in place and engage the bent tube nut to the side block fully until it is hand tight You may need ...

Page 10: ...a torque screwdriver carefully torque these screws to the correct torque for the helmet shell ALWAYS REFERENCE Appendix Contents Torque Specs startingonpageAPNDX 19inthemodularmanualto confirm correct torque 1 2 3 Oral Nasal Mask and Microphone Installation 1 Snap the oral nasal mask over the regulator mount nut Take extra care to make sure the mask has snapped into position all the way around the...

Page 11: ... the regulator may free flow without back pressure inside the oral nasal mask This is completely normal Placing a finger or hand over the outlet tube of the regulator will prevent free flow See 1 2 2 Adjusting the 455 Balanced Regulator on page 455BAL 3 in module 455 Balanced Regulator for proper adjustment NOTE For all maintenance and adjustment procedures refer to the 455 Balanced Regulator modu...

Page 12: ...nd in 525 620 Tool Kit 3 8 Drive Extension Minimum 3 in Length 1 Phillips Head Screwdriver Open End Wrench 7 16 and 2 7 8 and 11 16 Slip Joint Pliers and a Cloth 1 1 1 Bent Tube Removal 1 Always start removal at the side block end Loosen the tube with the 11 16 inch wrench The free swiveling mount nut on this end of the bent tube can be un threaded completely and can slide down the tube Always sta...

Page 13: ...ing nut 3 Slip the two O rings off the end of the shaft of the nose block device and slide the nose block device out through the oral nasal mask 1 1 3 Oral Nasal Mask and Microphone Removal 1 Verify that the nose block device is removed from the helmet 2 Push the microphone out of the oral nasal mask 3 Pull the oral nasal mask off the regulator mount nut It is held on by a snap fit 1 1 4 SuperFlow...

Page 14: ...final alignment of the regulator may have variation from unit to unit and this in no way will affect the function and or performance of the finished 455 regulator EXHAUST SYSTEM NOTE Each Quad and Tri Valve exhaust assembly can be removed and replaced onto the exhaust flange of the regulator as a complete unit If assembled using the indi vidual components special attention is required to ensure th...

Page 15: ... of the bent tube and the O ring at the demand regulator inlet side of the bent tube NOTE Before beginning the first step ensure that the jam nut located on the inlet nipple is turned entirely in towards the regulator body and away from the bent tube If it is not rotate jam nut to this correct starting position for bent tube installation 2 Lightly lubricate the O ring on the bent tube assembly 3 I...

Page 16: ...rting on page APNDX 19 in the modular manual to confirm correct torque 12 Attach the whisker to each side of the face port retainer using the spacers zinc anodes or kidney plates and screws Using a torque screwdriver carefully torque these screws to the correct torque for the helmet shell you are installing the whisker wings onto ALWAYS REFERENCE Appendix Contents Torque Specs startingonpageAPNDX ...

Page 17: ... the regulator may free flow without back pressure inside the oral nasal mask This is completely normal Placing a finger or hand over the outlet tube of the regulator will prevent free flow See 1 2 2 Adjusting the 455 Balanced Regulator on page 455BAL 3 in module 455 Balanced Regulator for proper adjustment NOTE For all maintenance and adjustment procedures refer to the 455 Balanced Regulator modu...

Page 18: ...driver 7 16 11 16 and 2 7 8 Open End Wrenches Slip Joint Pliers and a Cloth 1 1 1 Bent Tube Removal 1 Always start removal at the side block end Loosen the tube with the 11 16 inch wrench The free swiveling mount nut on this end of the bent tube can be un threaded completely and can slide down the tube Always start removal at the side block end 2 Loosen the lower bent tube nut by using the two 7 8...

Page 19: ... slide the nose block device out through the oral nasal mask 1 1 3 Oral Nasal Mask and Microphone Removal 1 Verify that the nose block device is removed from the Band Mask 2 Push the microphone out of the oral nasal mask 3 Pull the oral nasal mask off the regulator mount nut It is held on by a snap fit 1 1 4 SuperFlow 350 Removal from Helmet Mask 1 Verify that the bent tube has been removed from t...

Page 20: ...me variations Please be aware that the final alignment of the regulator may have variation from unit to unit and this in no way will affect the function and or performance of the finished 455 regulator EXHAUST SYSTEM NOTE Each Quad and Tri Valve exhaust assembly can be removed and replaced onto the exhaust flange of the regulator as a complete unit If assembled using the indi vidual components spe...

Page 21: ...ide the O ring end of the bent tube assembly into the regulator inlet nipple until the side block end is aligned with the threads for the bent tube mount nut 4 Ensure that the Teflon O ring is in place and engage the bent tube nut to the side block fully until it is hand tight You may need to gently rock the regulator body and or the bent tube to fully engage the side block nut 5 Thread the large ...

Page 22: ...ugh the oral nasal mask in the mask shell Install the nose block device through the interior of the oral nasal mask 3 Place both o rings on the shaft followed by the packing nut and the knob 4 Tighten the knob with the pliers padded by a cloth while holding the nose pad end inside the helmet with your hand 5 Tighten the packing nut with the 7 16 inch wrench until snug Do not over tighten as this w...

Page 23: ...Regulator Kit 1 505 776 455 Regulator Pod Assembly 1 510 403 Pod Gasket 1 510 747 Oral Nasal Mask 1 520 042 Tie Wrap 3 525 630 Tool Kit 455 Regulator 1 530 145 Lock Nut 8 555 155 Bent Tube w O rings 1 1 1 REX Pod System and Regulator Removal VIDEO How To Conversion Kit 455 Regulator for KM 77 Part 1 https www youtube com watch v RemxBjTTnlM Tools Required Regulator Mount Nut Tool P N 325 640 in To...

Page 24: ...T 6 5 Remove the nose block device as per 1 2 1 Nose Block Assembly Removal on page FCPRT 6 6 Remove the communication module from the helmet per 1 3 3 Removal of Communications Assembly on page COM 3 7 Remove the oral nasal mask by pulling it off the regulator mount nut NOTE That the bottom two nuts attach on the exterior of the pod while the remaining nuts attach on the interior of the pod 8 Loo...

Page 25: ... Required 3 8 Nut Driver or 3 8 Open End Wrench 5 32 Hex Key Ball End is Helpful 1 Locate the screws and washers that were used to secure the REX pod and set aside along with the lock nuts found in the conversion kit 2 Use the new gasket from the conversion kit to install onto the Regulator Mount Pod 350 Make sure that the ridge on the gasket is properly seated in the groove in the pod NOTE Thread...

Page 26: ...h along with the nut driver tighten the nuts gradually in a staggered pattern The lock nuts should be tightened to the point where the gasket can be seen just barely starting to extrude out squeeze out from between the pod and shell 1 2 2 455 Balanced Regulator Installation Tools Required Torque Wrench 7 8 and 11 16 Open End Attachments Socket Wrench Regulator Mount Nut P N 525 625 in Tool Kit Inc...

Page 27: ... using the indi vidual components special attention is required to ensure the exhaust valves are correctly orien tated and seated inside the exhaust whiskers If replacing valves or rebuilding the exhaust valve assembly by individual components see Quad Valve and Tri Valve section in our modular manual 1 Insert the opening on the exhaust main body onto the exhaust outlet of the water dump valve whi...

Page 28: ...block end of the bent tube and the O ring at the demand regulator inlet side of the bent tube NOTE Before beginning the first step ensure that the jam nut located on the inlet nipple is turned entirely in towards the regulator body and away from the bent tube If it is not rotate jam nut to this correct starting position for bent tube installation 2 Lightly lubricate the O ring on the bent tube ass...

Page 29: ...geAPNDX 19inthemodularmanualto confirm correct torque 10 Use a torque wrench inside the helmet with a 1 3 8 inch socket or regulator mount tool P N 525 625 found in the KMDSI tool kit P N 525 630 and extension to torque the regulator mount nut ALWAYS REFERENCE Appendix Contents Torque Specs starting on page APNDX 19 in the modular manual to confirm correct torque 11 Place a small amount of Loctite...

Page 30: ... 4 Tighten the knob with the pliers padded by a cloth while holding the nose pad end inside the helmet with your hand 5 Tighten the packing nut with the 7 16 inch wrench until snug Do not over tighten as this will make it difficult to slide the nose block device in and out 1 2 7 Chin Strap Replacement NOTE The adjustment strap should pull toward the right side of the helmet when it is on your head...

Page 31: ...ssing the purge button the regulator may free flow without back pressure inside of the oral nasal This is completely normal Placing a finger or hand over the outlet tube of the regulator will prevent free flow See 1 2 2 Adjusting the 455 Balanced Regulator on page 455BAL 3 in module 455 Balanced Regulator for proper adjustment NOTE For all maintenance and adjustment procedures refer to the 455 Bal...

Page 32: ...TM Kirby Morgan Dive Systems Inc 1430 Jason Way Santa Maria CA 93455 USA Telephone 805 928 7772 FAX 805 928 0342 E Mail KMDSI KirbyMorgan com Web Site www KirbyMorgan com ...

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