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Contents
455BAL-1 1.1 General 455BAL-11 1.4.4 Main Tube Components
Disassembly
455BAL-1 1.2 455 Balanced Regulator
Performance 455BAL-13 1.4.5 Regulator Body and
Exhaust Disassembly
455BAL-1 1.2.1 Test for Correct
Adjustment 455BAL-14 1.5 455 Balanced Regulator
455BAL-2 1.2.1.1 Purge Test Reassembly
© MMXXII Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 220223009 455BAL-1
455 Balanced Regulator Performance 455 Balanced Regulator
⅛"–¼"
the latest checklists at www.kirbymorgan.com or 4) Rotate the Flex Knob out counterclockwise
www.divelab.com. slowly, three full turns.
Check the regulator for adjustment and proper 5) Lightly depress the regulator purge cover sev-
function with the assembly complete, and at- eral times and ensure the gas flow is stable.
tached to a regulated gas supply (normally the
EGS system), adjusted to between 135–150 psig. The regulator may free flow when purged
This can be done with the bent tube in place or if there is no backpressure (resistance)
in the oral nasal, (e.g. the diver's face
with the bent tube and bent tube adapter re- is not correctly positioned into the oral
moved and gas supplied through a standard nasal mask). If the regulator free flows,
SCUBA hose. NOTE simply covering the air outlet tube
of the regulator inside the helmet or
BandMask® should stop any free flow.
Checking for proper adjustment of the 455
balanced regulator must be done with the 6) Push in gently on the cover of the regulator.
L.P. gas attached and turned on. There should be 1/8"–1/4" free travel in the cover
before gas flow starts. When the cover is fully de-
135 to 150 psig over ambient is the pressed, a strong surge of gas must be heard.
standard supply pressure to be used when
adjusting the 455 Balanced regulator.
NOTE 7) If the purge cover has NO play, or play is
greater than 1/4" BEFORE GAS flow is heard, the
1.2.1.1 Purge Test
demand regulator requires internal adjustment,
1) Rotate the flex knob in, clockwise towards the per "1.2.2 Adjusting the 455 Balanced Regulator"
regulator body, until a clicking can be heard with on page 455BAL-3.
each full turn of the knob.
1.2.1.2 Lever Play
1) Turn the adjustment knob all the way in,
This is an audible indication the tension of
the bias adjustment spring is as tight as it will clockwise toward the regulator.
get. The adjustment knob will never bottom
out or stop turning in this direction and no 2) Remove the regulator cover retainer assembly
damage to the mechanism will occur. The and diaphragm.
NOTE adjustment knob should only stop turning
when it is turned all the way out (counter
clockwise away from the regulator body). 3) Attach an L.P. supply to the regulator inlet or
helmet side block.
2) Attach an L.P. regulated gas supply to regula-
tor inlet or helmet side block. 4) Slowly turn on the gas supply.
455BAL-2 © MMXXII Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 220223009
455 Balanced Regulator 455 Balanced Regulator Performance
5) Rotate the flex knob out (counterclockwise) • 11/16 inch Open End Wrench
three full turns.
• 7/8 (2) inch Open End Wrench
6) Check lever arm play, there should be between
1/8 to 1/4 inch of free play in the lever and no gas The quickest and easiest way to supply
flow. gas to the regulator for testing in between
adjustments is to use a standard first
stage scuba regulator with an open ended
7) Depress the lever arm several times, ensure
standard second stage supply hose. The
a good flow and confirm the lever play does not NOTE
female fitting will thread onto the inlet
change. tube in place of the bent tube adapter.
If the lever play is outside the recommended pa- It is not necessary to remove the regulator from
rameters or if there is no strong gas flow when the helmet to perform field maintenance, howev-
the lever arm is depressed the regulator will re- er, for scheduled overhauls the regulator should
quire adjustment. be completely removed from the helmet and dis-
assembled. The design of this regulator also al-
1.2.2 Adjusting the 455 lows the technician to remove the main tube as
Balanced Regulator a complete unit for service or as a rapid replace-
ment in the field.
Tools required:
If there is too much play in the lever,
• Regulated air supply, 135 to 150 psig the adjustable nipple will need to be
turned out (counter clockwise). Too little
through standard SCUBA Second Stage
play, the nipple will need to be turned
Hose in (clockwise). If the purge cover can
NOTE
be pushed in further than ¹⁄₄" the nipple
• 1/4 inch Flat Head Screwdriver will need to be turned out slightly.
ADJUSTMENT
O-RINGS SHAFT
LOCK CLIP
JAM NUT DIAPHRAGM
EXHAUST VALVE INSERT
REGULATOR
REGULATOR PURGE COVER
EXHAUST VALVE COVER RETAINER
RETAINER RING FRAME REGULATOR
COVER GUARD
Exploded view of 455 Balanced regulator.
© MMXXII Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 220223009 455BAL-3
455 Balanced Regulator Removal from Helmet or BandMask 455 Balanced Regulator
Whatever direction is needed, make the adjust- Turning the adjustment nipple in
ment in very small increments and re-check af- (clockwise) will increase lever play and
increase the free range of the purge
ter each adjustment. Usually 1/16 turn at a time or cover. Turning the adjustment nipple out
less will suffice. Helpful
(counterclockwise) decrease lever play and
Hint
decreases the free range of the purge cover.
1) Remove the bent tube assembly, per "1.3.1 Re-
moval of the Bent Tube Assembly" on page BNT-4.
• Cutting Pliers
3) Turn the adjustment knob all the way in 1) Remove the bent tube assembly, per "1.3.1 Re-
(clockwise toward the regulator) then back out moval of the Bent Tube Assembly" on page BNT-4.
(counter clockwise) three full turns.
455BAL-4 © MMXXII Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 220223009
455 Balanced Regulator 455 Balanced Regulator Removal from Helmet or BandMask
Cut the tie wrap that connects the quad valve exhaust
main body to the water dump tube on the helmet pod.
6) Cut the tie wrap that connects the quad valve 8) The center section of the exhaust flange on
© MMXXII Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 220223009 455BAL-5
455 Balanced Regulator Disassembly 455 Balanced Regulator
the regulator body has a tie wrap holding it to stainless steel screws using a washer and lock
the helmet. Remove the tie wrap then stretch washer configuration. The two lower screws can
the main exhaust body off the regulator exhaust be changed to a bishop type pin which is stan-
flange. dard when using the KM 97 water shroud.
455BAL-6 © MMXXII Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 220223009
455 Balanced Regulator 455 Balanced Regulator Disassembly
• 1/4 inch Flat Blade Screwdriver Remove the bent tube adapter and O-ring.
• 7/8 inch Open End Wrench
3) Loosen the four screws on both sides of the
• 15/16 inch Open End Wrench regulator cover.
© MMXXII Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 220223009 455BAL-7
455 Balanced Regulator Disassembly 455 Balanced Regulator
455BAL-8 © MMXXII Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 220223009
455 Balanced Regulator 455 Balanced Regulator Disassembly
• Table Vise
• O-ring Pick
© MMXXII Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 220223009 455BAL-9
455 Balanced Regulator Disassembly 455 Balanced Regulator
“BOSS”
ADJUSTMENT
SHAFT
ADJUSTMENT
PACKING NUT
FLEX KNOB
WASHER
TRANSFER PIN
O-RING
The adjustment shaft must be completely re-
moved to allow the removal of the flex knob. DO
NOT ATTEMPT to SEPARATE THE KNOB and
PACKING NUT without FIRST REMOVING the
ADJUSTMENT SHAFT.
455BAL-10 © MMXXII Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 220223009
455 Balanced Regulator 455 Balanced Regulator Disassembly
© MMXXII Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 220223009 455BAL-11
455 Balanced Regulator Disassembly 455 Balanced Regulator
SPRING
BALANCED SPACER
BEARING CLIP
SEAT
INLET VALVE O-RINGS
ADJUSTMENT
NIPPLE
LEVER ARM
MAIN TUBE
Remove the balance spacer, spring and inlet Unscrew the adjustment nipple all the way
valve assembly from the main tube. out to free the threads from the main tube.
5) Using a flat blade screwdriver, unscrew the 6) Use the wooden dowel rod (chopstick) to push
adjustment nipple all the way out to free the it free.
threads from the main tube.
Carefully check the inlet nipple O-ring for
damage, even small cuts may cause leaking.
NOTE
Inspect all parts for signs of wear or
damage and replace if necessary.
455BAL-12 © MMXXII Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 220223009
455 Balanced Regulator 455 Balanced Regulator Disassembly
© MMXXII Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 220223009 455BAL-13
455 Balanced Regulator Reassembly 455 Balanced Regulator
S.S.
REGULATOR BODY
EXHAUST O-RING
VALVE
455BAL-14 © MMXXII Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 220223009
455 Balanced Regulator 455 Balanced Regulator Reassembly
FREE END
GAP
© MMXXII Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 220223009 455BAL-15
455 Balanced Regulator Reassembly 455 Balanced Regulator
VIDEO
https://www.youtube.com/
watch?v=-LXwsBR228k
Tools required:
• Christo-Lube® or Equivalent
• Table Vise
• A Rag or Cloth
Place the packing nut into a vise and insert the flex
knob into the adjustment packing nut at an angle.
© MMXXII Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 220223009 455BAL-17
455 Balanced Regulator Reassembly 455 Balanced Regulator
SPRING
BALANCED SPACER
BEARING CLIP
SEAT
INLET VALVE O-RINGS
ADJUSTMENT
NIPPLE
LEVER ARM
MAIN TUBE
455BAL-18 © MMXXII Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 220223009
455 Balanced Regulator 455 Balanced Regulator Reassembly
• Christo-Lube® or Equivalent
The wings that align with the lever arm are the
two that have an additional wall for the lever
Install the O-ring onto the main tube. arm to bear on. The valve assembly should be
inserted into the main tube with these walls to-
2) Install the two O-rings onto the balance spacer ward the bottom of the regulator tube.
and lubricate with Christo-Lube® or equivalent
and set aside.
B WARNING
DO NOT OVER LUBRICATE THE O-
RINGS ON THE BALANCE SPACER.
Excess lubrication could possibly col-
lect at the end of this part and block
the critical air balancing hole.
© MMXXII Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 220223009 455BAL-19
455 Balanced Regulator Reassembly 455 Balanced Regulator
Align and insert the inlet valve into the main tube.
If this is done properly, the lever should lift 8) Lightly lubricate the ends of the transfer pin
up when pressure is applied. If it does not, and install into the end of the balanced spacer.
NOTE
the valve has not been inserted correctly.
455BAL-20 © MMXXII Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 220223009
455 Balanced Regulator 455 Balanced Regulator Reassembly
© MMXXII Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 220223009 455BAL-21
455 Balanced Regulator Reassembly 455 Balanced Regulator
B CAUTION
If the adjustment nipple is screwed
into the main tube too far or until it
cannot go further, damage to the valve
seat is possible.
Thread the adjustment nipple into the main tube. 1.5.4 Installing the Main Tube
into the Regulator Body
14) Using a flat blade screwdriver, thread the
nipple into the tube slowly as soon as you see any Regulator should always be tested for proper
movement and/or drop of the lever, stop thread- adjustment once the Main Tube is installed.
NOTE
ing the nipple in.
Tools required:
• Torque Wrench
7/8 inch & 15/16 inch Open End Attachments
455BAL-22 © MMXXII Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 220223009
455 Balanced Regulator 455 Balanced Regulator Reassembly
© MMXXII Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 220223009 455BAL-23
455 Balanced Regulator Reassembly 455 Balanced Regulator
SECOND
6) Tighten the packing nut at the flex knob to the
torque specifications. See "Torque Specs" module.
It is important to do steps 5)
and 6) in this sequence.
NOTE
FIRST
5) Install the O-ring onto the bent tube adapter
and tighten adapter to the torque specifications.
See "Torque Specs" module.
NOTE
The hex nut will have to be unscrewed 8) Install the lock clip on the main tube.
a little more from the main tube to
allow for correct installation. Reinstall
the adapter and re torque.
455BAL-24 © MMXXII Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 220223009
455 Balanced Regulator 455 Balanced Regulator Reassembly
© MMXXII Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 220223009 455BAL-25
455 Balanced Regulator Reassembly 455 Balanced Regulator
455BAL-26 © MMXXII Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 220223009
455 Balanced Regulator Installing the 455 Balanced Regulator onto the Helmet or BandMask
• Torque Wrench
11/16, 7/8 inch Open End Attachments
• Torque Screwdriver
1/4 inch Flat Blade Attachment on Torque
Fit the regulator cover retainer Screwdriver
assembly onto regulator body.
• Christo-Lube® or equivalent oxygen compat-
ible lubricant
9) Torque the screws evenly. See "Torque Specs"
module.
1) Install the main exhaust body (with exhaust
whiskers attached) onto the exhaust flange of the
regulator body.
© MMXXII Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 220223009 455BAL-27
Installing the 455 Balanced Regulator onto the Helmet or BandMask 455 Balanced Regulator
Install the main exhaust body onto the Remove excess tie wrap.
exhaust flange of the regulator body.
Steps 3) and 4) apply to the
2) Install the tie wrap on the center section of the QUAD valve exhaust system
exhaust main body and tighten. Remove excess
tie wrap. 3) Pre-install a tie wrap onto the Quad Valve
exhaust main body. This will make installation
much easier and ensure a good seal.
455BAL-28 © MMXXII Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 220223009
455 Balanced Regulator Installing the 455 Balanced Regulator onto the Helmet or BandMask
© MMXXII Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 220223009 455BAL-29
Installing the 455 Balanced Regulator onto the Helmet or BandMask 455 Balanced Regulator
455BAL-30 © MMXXII Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 220223009
455 Balanced Regulator Installing the 455 Balanced Regulator onto the Helmet or BandMask
© MMXXII Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 220223009 455BAL-31