Kirby Morgan 525-757 User manual

Kirby Morgan Dive Systems, Inc.®
1430 Jason Way Santa Maria, California 93455
Phone: [phone] Fax: [phone]
www.KirbyMorgan.com email: [email protected]
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© MMXV Kirby Morgan Dive Systems, Inc. All Rights Reserved Document # 151006002 Page 1 of 8
Part #525-757
SuperFlow®450 Regulator Parts Upgrade Kit
Part # Description Qty
205-020 Inlet valve Assembly 1
210-055 O-ring 2
505-088 Adjustment Knob/Packing Nut Assembly 1
550-549 Spacer, Balanced 1
550-643 Transfer Pin 1
540-531 Lock Clip 1
NOTE: The upgrade kit assembly procedures are illustrated with the regulator body being shown removed
from the helmet. This is done only to emphasize and clarify the procedure. The regulator body can remain
in place (attached to the helmet) when completing the upgrade. THERE IS NO NEED TO REMOVE THE
REGULATOR BODY FROM THE HELMET to complete the following upgrade.
BCAUTION
Use only KMDSI original replacement parts. The use of other manufacturers' parts will inter-
fere with the performance characteristics of your life support equipment and may jeopardize
your safety. Additionally, any substitutions will void any warranties offered by KMDSI. When
ordering spares, always insist on Kirby Morgan Genuine Parts.
Tools Required:
Torque Screwdriver
Flat blade screwdriver attachment ¼"
Torque wrench
Open end attachments ⅞", ", 1", "
Open end wrench ⅞"
Christo-Lube®, Krytox®, Fluorolube®, or Tribolube®lubricants (one from the list).
To remove and replace the adjustment knob/packing assembly, bent tube assembly and front regulator
cover of the SuperFlow®450, these parts must be detached and the main tube must be removed from the
regulator main body.
Adjustment Flex Knob Removal
1. Remove the bent tube assembly from the helmet, per "1.1.2 Removal of the Bent Tube Assembly" on
page BNT-1.
2. Using a ⅞" wrench, remove the bent tube adapter and O-ring.

Kirby Morgan Dive Systems, Inc.®
1430 Jason Way Santa Maria, California 93455
Phone: [phone] Fax: [phone]
www.KirbyMorgan.com email: [email protected]
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© MMXV Kirby Morgan Dive Systems, Inc. All Rights Reserved Document # 151006002 Page 2 of 8
3. Remove the screws and washers on either side of the regulator
cover and unscrew the cover retaining ring.
4. Remove the cover and diaphragm. Inspect the diaphragm for holes or tears. If it is torn or punctured it
must be replaced. Inspect the interior of the regulator for foreign matter and clean if necessary.
5. Carefully insert the tip of a at blade screwdriver into the
slot at the top of the lock clip to free it from its locking posi-
tion and slide the clip away from the regulator main tube.
6. Using the 1" open end wrench, loosen the packing nut about 1 turn. Next, while fully depressing the
lever arm, grasp the ex knob and pull it straight out from the regulator body. This will remove all of
the main components of the regulator valve mechanism as a single, easy to handle unit.
NOTE: If the assembly does not break loose, lightly tap on the threaded end of the main tube with the plastic
handle of a screwdriver or plastic face hammer to avoid damaging the threads.

Kirby Morgan Dive Systems, Inc.®
1430 Jason Way Santa Maria, California 93455
Phone: [phone] Fax: [phone]
www.KirbyMorgan.com email: [email protected]
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© MMXV Kirby Morgan Dive Systems, Inc. All Rights Reserved Document # 151006002 Page 3 of 8
7. Unscrew the ex knob assembly from the main tube.
8. Remove the lever arm bearing clip, then remove the lever by gently pulling one leg out from the slot on
the main tube, followed by the second leg.
9. Slide the balance spacer, spring, and inlet valve assembly out from the main tube. Inspect main tube O-
ring, lever arm, bearing clip and inlet valve assembly for signs of wear or damage and replace if necessary.
Upgrade reassembly
BCAUTION
Install O-rings onto Balance Spacer prior to beginning reassembly. Be sure that the O-rings
on the Balance Spacer have been properly lubricated with one of the lubricants noted. Do not
over lubricate the O-rings. Excess lubrication could possibly collect at the end of this part and
block the critical air balancing hole.
1. Spread the arms of the lever just enough to install it onto the main tube.
OBSERVATION: Study the features of the inlet valve assembly. There are four “wings” towards one end
of the assembly and a bore that creates the balance chamber on the opposite end.
“WINGS”
AREA THE LEVER
FITS INTO, TOWARDS
BOTTOM OF TUBE
NOTE: The wings that align with the lever arm are
the two that have an additional wall for the lever arm
to bear on. The valve assembly should be inserted into
the main tube with these walls toward the bottom of the
regulator tube.
2. Insert the balance spacer with the two O-rings installed, insert the rst O-ring into the open end of the

Kirby Morgan Dive Systems, Inc.®
1430 Jason Way Santa Maria, California 93455
Phone: [phone] Fax: [phone]
www.KirbyMorgan.com email: [email protected]
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© MMXV Kirby Morgan Dive Systems, Inc. All Rights Reserved Document # 151006002 Page 4 of 8
inlet valve stainless steel tube and stop at the second O-ring. Next, align and insert the inlet valve into
the main tube, as noted above. If this is done properly, the lever should lift up. If it does not, the valve
has not been aligned correctly.
3. While holding the inlet valve in position, pinch each arm
of the lever and slowly remove the balance spacer and O-
rings. The inlet valve should remain in place. If it comes
out, repeat the process until the valve stays in place.
4. Install the spring and balance spacer with O-ring into the
main tube. Make sure the balance spacer is properly aligned
inside the main tube by pushing in on the end of the spacer
and slightly turning it with your nger tip to see that it
moves inward (i.e., it engages the hole in the inlet valve).
5. Lightly lubricate the ends of the transfer pin and install into the end of the balance spacer. Thread the
ex knob assembly onto the end of the main tube (closest to the lever arms) until it just stops. Hand
tighten the assembly and then back the assembly out three turns.

Kirby Morgan Dive Systems, Inc.®
1430 Jason Way Santa Maria, California 93455
Phone: [phone] Fax: [phone]
www.KirbyMorgan.com email: [email protected]
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© MMXV Kirby Morgan Dive Systems, Inc. All Rights Reserved Document # 151006002 Page 5 of 8
6. Install the bearing clip onto the outside of the main tube. Note that
there is a locating pin on the clip that must engage the correct hole on
the main tube. There are also small recesses on either side that the
legs of the lever arm t into. The clip is correctly positioned when it
is in the position shown.
NOTE: For ease of installation, the spring tension on the lever arm may
require the lever arm to be pulled more against the spring to align the
spacer.
Installing Main Tube into Regulator Body
1. Ensure O-ring on main tube is in good condition and lubricated with one
of the noted approved lubricants.
2. Lubricate the internal area of the regulator with approved lubricant
where the main tube O-ring will insert. This is important to help pre-
vent this O-ring from possibly getting cut when it is installed.

Kirby Morgan Dive Systems, Inc.®
1430 Jason Way Santa Maria, California 93455
Phone: [phone] Fax: [phone]
www.KirbyMorgan.com email: [email protected]
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© MMXV Kirby Morgan Dive Systems, Inc. All Rights Reserved Document # 151006002 Page 6 of 8
3. Install the main tube into the regulator body. Install the O-ring and the
bent tube adapter and tighten to the torque specications from the correct
Table (by model) in Appendix Contents, Torque Specs on page APNDX-19.
4. Tighten the packing nut at the ex knob with a " wrench to the
torque specications from the correct Table (by model) in Appendix
Contents, Torque Specs on page APNDX-32. Turn in the ex knob until an
audible click is heard then out three full turns. This is typically very
close to optimum adjustment.
5. Test the regulator for proper adjustment. Follow the procedures in "1.1.3 455 Balanced Demand Regula-
tor Test for Correct Adjustment, Fully Assembled" on page 455BAL-1.
NOTE: If using a Superow® 450 that was purchased before May 2015 the Packing Lock Clip P/N 540-531
will appear to have a different shape than the one included in this kit. They are the same part, use the same
P/N, but have undergone a slight design change.
6. Install the packing lock clip on the main tube, reinstall the diaphragm and cover assembly. Tighten the
screws to the torque specications from the correct table in the Appendix Torque Specs on page APNDX-32.
7. If necessary, adjust the regulator per "1.1.4 Adjusting the 455 Balanced Regulator" on page 455BAL-2.
8. Reinstall the bent tube assembly as per "1.1.4 Reinstallation of the Bent Tube Assembly" on page BNT-2.

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TM
Kirby Morgan Dive Systems, Inc.
1430 Jason Way
Santa Maria, CA 93455, USA
Telephone [phone], FAX [phone]
E-Mail: [email protected], Web Site:www.KirbyMorgan.com