455 Balanced Regulator General

455 Balanced Regulator

Contents
455BAL-1 1.1 455 Balanced Regulator 455BAL-12 1.1.6 455 Balanced Regulator
455BAL-1 1.1.1 General Removal

455BAL-1 1.1.2 455 Balanced Regulator 455BAL-13 1.1.7 455 Balanced Disassembly
Performance 455BAL-16 1.1.8 Assembly of the 455
455BAL-1 1.1.3 455 Balanced Demand Balanced Regulator
Regulator Test for Correct 455BAL-17 1.1.8.1 Assembly of the Flex Knob
Adjustment, Fully Assembled 455BAL-17 1.1.8.2 Installing the Flex Knob
455BAL-2 1.1.4 Adjusting the 455 Balanced 455BAL-18 1.1.9 Assembly of 455 Balanced
Regulator Regulator
455BAL-4 1.1.5 455 Balanced Regulator Bias 455BAL-21 1.1.10 455 Balanced Regulator
Adjustment Field Service with Installation
Demand Regulator on Helmet

1.1 455 Balanced Regulator the latest checklists at www.kirbymorgan.com or

1.1.1 General
The 455 Balanced Regulator is an ultra-high per-
formance regulator, continuing the long line of
exceptional regulators from Kirby Morgan®. Its
construction and materials make it an extremely
rugged regulator.
www.divelab.com.
Check the regulator for adjustment and proper
function with the assembly complete, and sup-
plied with a breathing gas supply pressure of be-
tween 135 to 150 p.s.i.g

NOTE: When storing the helmet for any length
of time, ensure that the Flex Knob, for adjusting
the regulator, is turned “out” fully counterclock-
wise to avoid stressing the bias springs. This will
prolong the life of both the inlet valve, seat, and
bias spring.
1.1.2 455 Balanced Regulator
Performance
The 455 Balanced Regulator is an all stainless
steel regulator of a balanced design that offers
far greater overall breathing performance than
the non-balanced SuperFlow® and SuperFlow®
350 regulator.
NOTE: 135 to 150 p.s.i.g. over ambient is the
standard supply pressure to be used when
adjusting the 455 Balanced regulator.
1) Rotate the flex knob in, clockwise towards the
regulator body, until a clicking can be heard with
each full turn of the knob. This is an audible indi-
cation the tension of the bias adjustment spring
is as tight as it will get. The adjustment knob will
never bottom out or stop turning in this direction
and no damage to the mechanism will occur. The
clicking is an audible indication the adjustment
knob is fully positioned. Listen carefully for this
indicating click.

1.1.3 455 Balanced Demand Regulator
Test for Correct Adjustment, Fully
Assembled
To maintain optimum performance of the de-
mand regulator, it should be checked for proper
function and adjustment prior to commencement
of diving each diving day, in accordance with the
KMDSI Daily Set Up and Functional Checklist.
See the Kirby Morgan® or Dive Lab websites for
2) Ensure the supply pressure is connected and
properly adjusted to 135 to 150 p.s.i.g.
3) Turn on the gas supply.
4) Rotate the Flex Knob out counterclock-
wise slowly, three full turns.
5) Lightly depress the regulator purge cover sev-
eral times and ensure the gas flow is stable.

© MMXIV Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 140425002 455BAL-1
 
Adjusting the 455 Balanced Regulator 455 Balanced Regulator

NOTE: The regulator may free flow when purged

if there is no backpressure (resistance) in the oral
nasal, (e.g. the diver's face is not correctly posi-
tioned into the oral nasal mask). If the regula-
tor free flows, simply covering the air outlet tube
of the regulator inside the mask should stop any
free flow.

6) Push in gently on the cover of the regulator.

There should be 1/8"–1/4" free travel in the cover
before gas flow starts. When the cover is fully de-
pressed, a strong surge of gas must be heard.

7) If the purge cover has NO play, or play is

greater than 1/4" BEFORE GAS flow is heard, the
demand regulator requires internal adjustment,
per "1.1.4 Adjusting the 455 Balanced Regulator"
on page 455BAL-2.

1.1.4 Adjusting the 455 Balanced

Regulator
Tools required:
Air supply, 135/150 psig through standard
SCUBA second stage hose
Flat blade screwdriver
11/16 inch Open-end Attachment on Torque Wrench
7/8 inch Open-end Attachment on Torque Wrench
7/8 inch Open-end Wrench

Remove the bent tube and the bent tube adapter.

1) Remove the bent tube assembly from the hel-

met.

Remove the bent tube adapter

2) Remove the bent tube adapter.

455BAL-2 © MMXIV Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 140425002
455 Balanced Regulator Adjusting the 455 Balanced Regulator

3) Attach L.P. supply to the regulator (std. SCU-

BA hose end)
Note: There are two ways to supply air to the reg-
ulator when performing adjustments. The quick-
est and easiest way is to use a standard first
stage SCUBA regulator with a standard second
stage supply hose having a 9/16" straight thread
female fitting. The female fitting will thread onto
the inlet tube in place of the bent tube adapter.
4) Slowly turn on the air supply and check lever
arm play. With the adjustment knob adjusted
out three full turns, and gas pressure of 135-150
psig to the inlet valve, there should be between
1/8 and 1/4 inch of free play in the lever and no gas
flow. Depress the regulator purge cover several
times, ensure a good flow and ensure the lever
play does not change.

⅛"–¼"

Diagram of maximum lever arm travel.

5) Turn off the air supply and bleed off the pres-
sure and remove the supply hose to expose the
adjustment nipple. Insert a flat head screwdriver
into the slot in the end of the adjustment nipple
to make adjustments as necessary.

6) If there is too much play in the lever, the ad-

justable nipple will need to be turned out (counter
clockwise). Too little play, the nipple will need to
be turned in. Whatever direction is needed, make
the adjustment in very small increments and re-
check. Usually 1/16 turn at a time or less will suf-
fice.

7) If adjustment is necessary, turn off the air

supply, bleed off the pressure, then remove the
supply hose to expose the adjustment nipple. In- Turn the adjustment nipple 1/16 of a turn at a time to
sert a 1/4 inch wide flat head screwdriver into the adjust the performance of the regulator.
slot in the end of the adjustment nipple to make
adjustments as necessary.

8) Re-connect air supply and re-check , (repeat

steps 5) through 8) as necessary), until required
play is obtained.

© MMXIV Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 140425002 455BAL-3
455 Balanced Regulator Bias Adjustment Field Service with Demand Regulator on Helmet 455 Balanced Regulator

O-ring or inlet valve seat. (See trouble shooting

tips).

10) Once the regulator is properly adjusted, rein-

stall the bent tube adapter and O-ring. Tighten
the adapter in accordance with the torque speci-
fication found in the correct Table (correct model)
of the manual Appendix. See Appendix Contents:
Torque Specs starting on page APNDX-19.

11) Reinstall the bent tube assembly as per "Re-

installation of the Bent Tube Assembly" on page
BNT-2.

1.1.5 455 Balanced Regulator Bias

Before you reinstall the bent tube, connect the low
pressure hose to the regulator and pressurize it again.
Push in on the regulator cover 1/8–1/4". The regulator
should just begin to free flow if it is properly adjusted.
Adjustment Field Service with Demand
Regulator on Helmet
It is not necessary to remove the regulator from
the helmet to perform field maintenance. Howev-
er for scheduled overhauls the regulator should
be completely removed from the helmet and dis-
assembled.

9) If you are unable to obtain a proper adjustment Tools and Parts Required:
with the regulator following this procedure, or a 1/4 inch Flat Blade Screwdriver on Torque Wrench
steady flow of gas seems to be leaking, you will 15/16" Open End Attachment on Torque Wrench
need to disassemble the regulator to check the 7/8" wrench
condition of the lever and possibly for a damaged

ADJUSTMENT
O-RINGS SHAFT

NOTE: two LP plugs for manufactur-

er’s test purposes only. Do not remove PACKING NUT
unless O-rings require replacement. FLEX KNOB
WASHER
BEARING CLIP
SEAT TRANSFER PIN
ADJUSTMENT BALANCE SPACER
NIPPLE INLET VALVE
O-RING
LEVER
BENT TUBE
ADAPTER MAIN TUBE

LOCK CLIP
JAM NUT DIAPHRAGM
EXHAUST VALVE INSERT
REGULATOR
EXHAUST VALVE REGULATOR PURGE COVER
COVER RETAINER
RETAINER RING FRAME REGULATOR
COVER GUARD
Exploded view of 455 Balanced regulator.

455BAL-4 © MMXIV Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 140425002
455 Balanced Regulator
7/8" torque wrench
Balance Spacer, P/N 550-549 with two O-rings ,
P/N 210-055 installed
Wooden Dowel Rod
1) Remove the bent tube assembly from the hel-
met, per "1.1.2 Removal of the Bent Tube Assem-
bly" on page BNT-1.
2) Using a 7/8" wrench, remove the bent tube
adapter and O-ring. Be careful not to lose the O-
ring.
Loosen the screws and washers on either side of the
cover.
3) Loosen the four screws and washers on either
side of the regulator cover. These four screws
should NOT be removed from the cover assem-
bly. The cover assembly is designed to retain the
screws to prevent loss. Un-thread the screws only
enough to allow the cover assembly to separate
© MMXIV Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 140425002
455 Balanced Regulator Bias Adjustment Field Service with Demand Regulator on Helmet
from the main body of the regulator to expose the
interior parts.
Remove the diaphragm and inspect it carefully. If it
is torn or punctured it must be replaced.
4) Remove the cover assembly and diaphragm.
Inspect the diaphragm for holes or tears. If it
torn or punctured it must be replaced. Inspect
the interior of the regulator for foreign matter
and clean if necessary.
Carefully insert the tip of a small flat blade
screwdriver into the slot at the top of the lock clip to
loosen it.
Note: The two holes for the LP plugs seen on the right
side of the 455 regulator body in the photo above
are for manufacturer’s test purposes only. These
two plugs should be left in place unless the O-rings
require replacement.
455BAL-5
 
455 Balanced Regulator Bias Adjustment Field Service with Demand Regulator on Helmet 455 Balanced Regulator

When you pull the flex knob assembly out, the main
tube and related parts will follow.

Slide the clip away from the regulator main tube.

6) Using the 1" open end wrench, loosen the pack-
ing nut about 1 turn. Next, while fully depress-
5) Carefully insert the tip of a small flat blade
ing the lever arm, grasp the flex knob and pull it
screwdriver into the slot at the top of the lock
straight away from the regulator body. This will
clip to loosen it and slide the clip away from the
remove all of the main components of the regula-
regulator main tube.
tor valve mechanism as a single, easy to handle
unit.

Separate the flex knob assembly from the main tube.

You must hold the lever down to remove all main

components as a sub assembly.

455BAL-6 © MMXIV Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 140425002
455 Balanced Regulator 455 Balanced Regulator Bias Adjustment Field Service with Demand Regulator on Helmet

The transfer pin may fall from the end of the shaft. Be
careful not to loose it.

7) Unscrew the flex knob assembly from the main

9) Remove the lever arm bearing clip.
tube. The transfer pin may fall from the end of
the shaft. Be careful not to lose it.

10) Remove the lever by gently pulling one leg

out from the slot on the main tube, followed by
the second leg.

Remove the O-ring from the flex knob packing nut.

You can use a credit card, toothpick, or any clean soft
device that will not damage the O-ring or the nut.

8) Remove the O-ring from the flex knob assem-

bly packing nut. Inspect for signs of wear and re-
place if necessary. Otherwise, if it is in good con-
dition, set it aside for cleaning and lubrication.

Remove the balance spacer, spring and inlet valve

assembly from the main tube.

11) Slide the balance spacer, spring, and inlet

valve assembly out from the main tube.

© MMXIV Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 140425002 455BAL-7
 
455 Balanced Regulator Bias Adjustment Field Service with Demand Regulator on Helmet 455 Balanced Regulator

Do not over lubricate the O-rings on the balance

spacer.

17) Install the two O-rings onto the balance spac-

er. DO NOT OVER LUBRICATE THESE O-
Unscrew the adjustment nipple (turn it “out”) from RINGS. Excess lubrication could possibly collect
the main tube. Use the wooden dowel rod to push it at the end of this part and block the critical air
free. balancing hole.
12) Unscrew the adjustment nipple (turn it “out”) 18) Spread the arms of the lever just enough to
from the main tube. Use the wooden dowel rod install it onto the main tube.
to push it free. Carefully check the inlet nipple
O-ring for damage, even small cuts may cause
leaking AREA THE LEVER
13) Inspect all parts for signs of wear or damage
FITS INTO, TOWARDS
and replace if necessary. BOTTOM OF TUBE
14) Clean all parts per "Routine Maintenance"
on page FRNT-36. Replace any parts if damage
is present or suspected. If a normal overhaul is
being conducted replace all soft goods. Lubricate
O-rings and moving parts with a light coating of
Christo-Lube®, Krytox®, Fluorolube®, or Tribol-
ube® are also acceptable lubricants. It is not nec- “WINGS”
essary to disassemble the flex knob assembly.

15) Install the O-ring onto the adjustment nipple
if you have not already done so. Be sure that the
O-ring has been properly lubricated with Chris-
to-Lube® or other lubricants noted in step 14).
16) Install the O-ring onto the main tube.
Close-up detail of the inlet valve.
19) Study the features of the inlet valve assem-
bly. There are four “wings” towards one end of
the assembly and a bore that creates the balance
chamber on the opposite end.

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

455BAL-8 © MMXIV Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 140425002
455 Balanced Regulator
be inserted into the main tube with these walls
toward the bottom of the regulator tube.
Using the balance spacer with the two O-rings
installed, insert the first O-ring into the open end of
the inlet valve.
Align and insert the inlet valve into the main tube.
20) Using the balance spacer with the two O-
rings installed, insert the first O-ring into the
open end of the inlet valve stainless steel tube
and stop at the second O-ring. Now align and in-
sert 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 in-
serted correctly.
© MMXIV Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 140425002
455 Balanced Regulator Bias Adjustment Field Service with Demand Regulator on Helmet
While holding the inlet valve in position, pinch each
arm of the lever and slowly remove the balance spacer
and O-rings.
21) 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.
Install the spring and balance spacer with O-ring
into the main tube.
22) Install the spring and balance spacer with
O-ring into the main tube. Make sure the bal-
ance spacer is properly aligned inside the main
tube by pushing in on the end of the spacer and
slightly turning it with your finger tip, to see that
it moves inward (i.e., it engages the hole in the
inlet valve).
455BAL-9
 
455 Balanced Regulator Bias Adjustment Field Service with Demand Regulator on Helmet 455 Balanced Regulator

Install the transfer pin then install the flex knob Install the bearing clip onto the outside of the main
assembly about four turns. tube.

23) Lightly lubricate the ends of the transfer pin
and install into the end of the balance spacer.
Thread the flex 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.
24) 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 fit into.
The clip is correctly positioned when it is in the
position shown. The square opening on the main
tube must be exposed.

455BAL-10 © MMXIV Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 140425002
455 Balanced Regulator 455 Balanced Regulator Bias Adjustment Field Service with Demand Regulator on Helmet

SPRING

SPACER
BEARING CLIP
SEAT
INLET VALVE O-RINGS

ADJUSTMENT
NIPPLE

LEVER ARM
MAIN TUBE

O-RINGS
Details of the 455 Balanced main tube and associated parts.

25) Lightly lubricate the O-ring and insert the

adjustment nipple into the main tube on the end
opposite the adjustment knob. Using a flat blade
screwdriver, thread the nipple into the tube slow-
ly.

Tip: As soon as you see any movement and/or

drop of the lever, stop threading the nipple
in.

26) Make sure the two main tube O-rings and

packing O-ring have been installed and lightly
Thread the adjustment nipple into the main tube.
lubricated. Then depress the lever down and
carefully install the main tube assembly into
the body, and adjustment knob (flex knob) into
the regulator, until the threaded end of this as-
sembly comes completely through to the opposite
side of the regulator body. Make sure the HEX
flat area aligns to the mating HEX in the regula-
tor body. This will be evident by having the lever
arm oriented correctly in relation to the top of the
regulator.

NOTE: It is important to do steps 27) and

28) in this sequence.

Using a flat blade screwdriver, thread the nipple into

the tube slowly.

© MMXIV Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 140425002 455BAL-11
455 Balanced Regulator Removal  455 Balanced Regulator

1.1.6 455 Balanced Regulator Removal

Required Tools:
11/16 inch Open-end Attachment on Torque Wrench
7/8 inch Open-end Wrench
7/8 inch Open-end Attachment on Torque Wrench
1 3/8 inch Socket
1/4 inch Flat Blade Attachment on Torque Screw-
driver
Medium Blade Screwdriver

1) Remove the bent tube assembly, per "1.1.2 Re-

moval of the Bent Tube Assembly" on page BNT-1.

Install the O-ring in the bent tube adapter.

First
27) Install the O-ring and the bent tube adapter
and tighten to the torque specifications from the
correct Table (by model) in Appendix Contents,
Torque Specs on page APNDX-19.

Second
28) Tighten the packing nut at the flex knob with a
one inch wrench to the torque specifications from
the correct Table (by model) in Appendix Contents,
Torque Specs on page APNDX-19. Turn in on the
flex knob until an audible click is heard then out
three full turns. This is typically very close to op-
timum adjustment.

29) Check the adjustment of the regulator using

Be sure to remove and set aside the whisker spacers.
recommended air pressure (check lever arm play
when pressurized). If you followed the, “tip” not-
2) Remove the screws, anodes or kidney plates
ed in step 25), the regulator should be very close
and whisker spacers from the whiskers.
to correctly adjusted, if not already correctly ad-
justed.
3) Remove the nose block device per "Nose Block
Assembly Removal" on page FCPRT-5.
30) Install the lock clip on the main tube, rein-
stall the diaphragm and cover assembly. Tighten
4) Remove the oral nasal mask per "Oral Nasal
the screws to to the torque specifications from the
Mask Removal" on page ON-1.
correct Table (by model) in Appendix Contents,
Torque Specs on page APNDX-19.
5) The regulator mount nut is removed along
with the sealing O-ring.
31) If necessary, adjust the regulator per "1.1.4
Adjusting the 455 Balanced Regulator" on page
455BAL-2.

32) Reinstall the bent tube assembly as per "1.1.4

Reinstallation of the Bent Tube Assembly" on
page BNT-2.

455BAL-12 © MMXIV Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 140425002
455 Balanced Regulator 455 Balanced Disassembly

Remove the tie wrap.

Cut the tie wrap that connects the regulator body to

the water dump tube on the helmet pod.

6) Cut the tie wrap that connects the regulator

body to the water dump tube on the helmet pod.

Separate the regulator from the Quad Valve™ exhaust

whiskers.

8) The center section of the exhaust whisker,

named the Exhaust Main Body has a tie wrap
holding it in place. Remove the tie wrap then
stretch the body off the regulator exhaust flange.

1.1.7 455 Balanced Disassembly

Required Tools:
1" Open end attachment on torque wrench
1/4" Flat Blade Attachment on Torque Screwdriver
MINI flat blade screwdriver

1) See steps 2) on page 455BAL-5 through 7) on page

455BAL-7 for bent tube adapter, regulator cover,
diaphragm, lock clip, main tube and packing nut
removal and inspection instructions for the dia-
phragm.
Remove the regulator from the helmet.

7) Now the regulator assembly can be pulled out

of the helmet.

© MMXIV Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 140425002 455BAL-13
455 Balanced Disassembly  455 Balanced Regulator

NOT ATTEMPT TO SEPARATE THE KNOB

AND PACKING NUT WITHOUT FIRST RE-
“BOSS” MOVING THE ADJUSTMENT SHAFT.
ADJUSTMENT Hold the packing nut while turning the flex knob
SHAFT clockwise. You will notice the internal adjust-
ADJUSTMENT ment shaft will travel outward AWAY from the
PACKING NUT packing nut. It may be easier to place the hex of
FLEX KNOB the packing nut into a vise or pliers, but do not
over compress.
WASHER
This shaft may not fall out, so after about ten full
TRANSFER PIN turns of the knob, you may insert a small screw-
driver into the outer end of the flex knob and
O-RING push on the end of the adjustment shaft to allow
removal from the packing nut.
455 Balanced flex knob assembly.
NOTE: Using a solution of mild dish soap and
water and liberally wetting the packing nut and
flex knob will make separation and removal
much easier.

With the shaft out, the flex knob can be separated

from the packing nut.

3) With the shaft out, the flex knob can be sepa-

rated from the packing nut. Using the soap and
water solution, wet the rubber knob and packing
nut, then grab the packing nut with one hand or
vise, and the flex knob with the other and bend
to separate. There is a boss on the knob that will
pop loose from the packing nut.

The adjustment shaft must be completely removed to

allow the removal of the flex knob.

2) The adjustment shaft must be completely re-

moved to allow the removal of the flex knob. DO

455BAL-14 © MMXIV Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 140425002
455 Balanced Regulator
Using an O-ring pic, carefully remove the bearing
washer and adjustment shaft O-ring.
4) Using an O-ring pic, carefully remove the bear-
ing washer and adjustment shaft O-ring from the
packing nut and discard the O-ring.
5) See steps 9) on page 455BAL-7 through 13)
on page 455BAL-8 for lever arm bearing clip,
lever arm, balance spacer, spring, inlet valve as-
sembly and adjustment nipple removal.
© MMXIV Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 140425002
455 Balanced Disassembly
Remove the two O-rings from the balance spacer.
6) Remove the two O-rings from the balance
spacer.
Remove the O-ring from the main tube.
7) Remove the O-ring from the main tube.
NOTE: Check the condition of this O-ring very
carefully. If there are any signs of damage, it
must be replaced. A leak stemming from this O-
ring may sound like the adjustment nipple and
inlet valve seat are not sealing; however, that
may not be the source. Pay close attention to this
seal!
455BAL-15
Assembly of the 455 Balanced Regulator  455 Balanced Regulator

Remove the exhaust valve insert retainer ring from

the regulator body. Remove the sealing O-ring.

8) Remove the exhaust valve insert retainer ring 9) Remove the exhaust valve assembly and its
from the regulator body. sealing O-ring from the regulator body and sepa-
rate the exhaust valve from the insert.

10) Inspect all parts for signs of wear or damage

and replace if necessary. Replace all O-rings and
soft goods if a standard overhaul is being con-
ducted.

11) Clean all parts per "General Cleaning Guide-

lines" on page FRNT-42. Lubricate O-rings and mov-
ing parts with a light coating of Christo-Lube®.

1.1.8 Assembly of the 455 Balanced

Regulator
Required Tools:
11/16 inch Open-end Attachment on Torque Wrench
7/8 inch Torque Wrench
7/8 inch Open-end Wrench Attachment on Torque
Remove the exhaust valve insert assembly. Wrench
1 1/4 inch Flat Blade Attachment on Torque Screw-
driver
1/4–3/8 inch Flat Blade Screwdriver

455BAL-16 © MMXIV Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 140425002
455 Balanced Regulator
1.1.8.1 Assembly of the Flex Knob
PACKING NUT
BEARING WASHER
SHAFT O-RING
Install the larger O-ring over external packing nut
groove and the smaller O-ring into internal packing
nut groove
1) Lubricate the smaller, shaft O-ring with Chris-
to-Lube® or equivalent oxygen compatible lubri-
cant, and install into the internal O-ring groove
of packing nut.
2) Install bearing washer on the top of the O-ring
and press down until it is flat.
1.1.8.2 Installing the Flex Knob
1) Begin by lightly lubricating the groove in the
end of the flex knob where it presses into the
packing nut with Christo-Lube® or equivalent
oxygen compatible lubricant.
Insert the knob into the packing nut at an angle as
shown using your hand or a vise.
© MMXIV Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 140425002
Assembly of the 455 Balanced Regulator
Using a wide slotted screwdriver, push the rest of the
flex knob into the packing nut.
2) Place the packing nut into a vise, or by hand,
insert the knob into the packing nut at an angle
as shown. Twisting the knob may allow the rub-
ber to insert further into the packing nut. While
holding the knob in this position, and using a
wide slotted screwdriver, push the rest of the flex
knob into the packing nut.
Lubricate threads on adjustment shaft with Christo-
Lube® and insert into flex knob
3) Next, lubricate the threads of the adjustment
shaft with Christo-Lube® and insert into the flex
knob. Push on the adjustment shaft’s end while
turning the flex knob counterclockwise to engage
threads. Continue turning the flex knob counter-
clockwise until the flex knob stops.
4) Lubricate the larger packing nut O-ring with
455BAL-17
Assembly of 455 Balanced Regulator  455 Balanced Regulator

Christo-Lube® and install into the external O-

ring groove of the packing nut.

Install the new exhaust valve into the insert. Use care
to ensure the valve is mated to the proper side of the
exhaust insert.

3) Install the new exhaust valve into the exhaust

valve insert. Use care to ensure the valve is mat-
ed to the proper side of the exhaust valve insert.
Push in on the adjustment shaft while turning the The exhaust valve installs on the side that has
flex knob counterclockwise to engage threads the ring support.

1.1.9 Assembly of 455 Balanced

Regulator

Install the O-ring and valve insert.

4) Drop the exhaust valve insert with exhaust

valve installed on top of the O-ring. The exhaust
The regulator body must be clean and free of foreign valve insert must be oriented so that it seals
matter. against the O-ring and the exhaust valve will
mate properly with the insert.
1) Inspect the interior of the regulator body and
make sure that it is clean and there is no foreign
matter.

2) Install the O-ring for the exhaust valve insert,

into the regulator body.

455BAL-18 © MMXIV Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 140425002
455 Balanced Regulator Assembly of 455 Balanced Regulator

6) Cut off any excess tail from the exhaust valve

that protrudes into the regulator body.
FREE END

GAP

Install the retainer clip.

5) Install the retainer clip. Use a flat blade screw-

driver to push the retainer clip into the opening To test to see if the insert is installed properly, try to
in the regulator body for the exhaust valve in- spin the insert. It should be difficult, or not able to
turn.
sert. The clip should lock into place. Make sure it
is pressed into the groove completely. This is ex-
To test to see if the insert is installed properly,
tremely important to prevent the exhaust compo-
try to spin the insert. It should be difficult, or not
nents from becoming dislodged. The ends of the
able to turn. You should not be able to dislodge
ring should have a gap between them.
the insert by hand. Friction between the insert,

EXHAUST O-RING
VALVE

EXHAUST VALVE INSERT

RETAINER RING
455 Balanced exhaust valve mechanism.

© MMXIV Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 140425002 455BAL-19
Assembly of 455 Balanced Regulator  455 Balanced Regulator

the O-ring and the regulator body should hold

the insert in its proper position. Also check to be
certain the exhaust valve will not get caught on
the free end of the retainer clip (see photo).

Install the O-ring on the inlet nipple.

9) Install the O-ring on the adjustment nipple.

Lubricate with Christo-Lube®.

10) Install the two O-rings on the balance spacer.

Install the O-ring on the main tube. Lubricate with Lubricate with Christo-Lube®.
Christo-Lube®.
11) See the remainder of the main tube assembly
7) Install the O-ring on the main tube. Lubricate
and installation procedure starting on step 17)
with Christo-Lube® or equivalent oxygen compat-
on page 455BAL-8.
ible lubricant.

Lubricate the internal area of the regulator with

Christo-Lube®.

8) Lubricate the internal area of the regulator

with Christo-Lube® where the main tube O-ring
will insert. This is important to help prevent this
O-ring from possibly getting cut when it is in-
stalled.

455BAL-20 © MMXIV Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 140425002
455 Balanced Regulator 455 Balanced Regulator Installation

13) Test the regulator for proper adjustment.

Follow the procedures in "1.1.3 455 Balanced
Demand Regulator Test for Correct Adjustment,
Fully Assembled" on page 455BAL-1.

1.1.10 455 Balanced Regulator

Installation
Required Tools:
11/16 inch Open-end Attachment on Torque Wrench
7/8 inch Open-end Wrench Attachment on Torque
Wrench
7/8 inch Open-end Torque Wrench
1 3/8 inch Socket
1/4 inch Flat Blade Attachment on Torque Screw-
driver

Begin by installing the regulator at an angle, as

shown, to the main exhaust body.

Install the diaphragm, cover assembly and cover

retaining screws.

12) Install the diaphragm, cover assembly and

cover retaining screws. Tighten the screws to 15
to 18 inch pounds.

© MMXIV Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 140425002 455BAL-21
 
455 Balanced Regulator Installation
Install the tie wrap on the regulator.
Remove excess tie wrap.
1) Install the tie wrap on the center section of
the exhaust whisker, (the exhaust main body)
and tighten. Remove excess tie wrap.
455BAL-22 © MMXIV Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 140425002
455 Balanced Regulator
Insert the tube on the exhaust main body onto the
tube of the helmet pod.
Seal with a tie wrap.
2) Insert the tube on the exhaust main body onto
the tube of the helmet pod for the water dump
valve, while at the same time aligning and insert-
ing the threaded mounting tube on the regulator,
into the mounting hole on the pod. Seal with a tie
wrap. Remove excess tie wrap.
455 Balanced Regulator
Install the O-ring that mounts on the regulator tube
inside the helmet.
Install the regulator mount nut. DO NOT FULLY
TIGHTEN THE NUT AT THIS TIME.
3) Install the sealing O-ring and regulator mount
nut. DO NOT FULLY TIGHTEN THE NUT AT
THIS TIME.
4) Make sure the rubber tube is installed prop-
erly on the water dump tube on the pod.
5) Install the bent tube assembly, per "1.1.4 Re-
© MMXIV Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 140425002
455 Balanced Regulator Installation
installation of the Bent Tube Assembly" on page
BNT-2.
6) Tighten the regulator mount nut in accordance
with the torque specification found in the correct
Table (correct model) of the manual Appendix.
See Appendix Contents: Torque Specs starting
on page APNDX-19.
7) Install the oral nasal mask per "1.1.3 Oral Na-
sal Mask Replacement" on page ON-2.
8) Install the nose block device per "1.2.2 Nose
Block Device Replacement" on page FCPRT-6.
9) Install the screws, kidney plates and whisker
spacers from the whiskers. Tighten the screws in
accordance with the torque specification found in
the correct Table (correct model) of the manual
Appendix. See Appendix Contents: Torque Specs
starting on page APNDX-19.
455BAL-23