1.1 455 Balanced Regulator1.1.1 GeneralThe 455 Balanced Regulator is another high per-formance regulator from Kirby Morgan. Its con-struction and materials make it an extremely rugged regulator.
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 PerformanceThe 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.
1.1.3 455 Balanced Demand Regulator Test for Correct Adjustment, Fully AssembledTo 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 Dive Lab website for the latest checklists at 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: 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.
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.
NOTE: The regulator may free flow when purged if there is no backpressure (resistance) in the oral
Adjusting the 455 Balanced Regulator 455 Balanced Regulator
nasal, (e.g. the diver's face is not correctly posi-tioned in the oral nasal mask). If the regulator does free flow, 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 RegulatorTools required:Air supply, 135/150 psig through standard SCUBA second stage hoseFlat blade screwdriver11/16 inch Open-end Attachment on Torque Wrench 7/8 inch Open-end Attachment on Torque Wrench7/8 inch Open-end Wrench
Remove the bent tube and the bent tube adapter.
1) Remove the bent tube assembly from the hel-met.
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, insure 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 slot in the end of the adjustment nipple to make adjustments as may be 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 of a turn will suffice.
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-sert a 1/4 inch wide flat head screwdriver into the 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.
Turn the adjustment nipple 1/16 of a turn at a time to adjust the performance of the regulator.
455 Balanced Regulator Bias Adjustment Field Service with Demand Regulator on Helmet 455 Balanced Regulator
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.
9) If you are unable to obtain a proper adjustment with the regulator following this procedure, or a steady flow of gas seems to be leaking, you will need to disassemble the regulator to check the condition of the lever and possibly for a damaged
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 to 80 inch pounds.
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 Adjustment Field Service with Demand Regulator on HelmetIt 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.
Tools and Parts Required:1/4 inch Flat Blade Screwdriver on Torque Wrench 15/16" Open End Attachment on Torque Wrench7/8" wrench7/8" torque wrenchBalance Spacer, P/N 550-549 with two O-rings , P/N 210-055 installed
455 Balanced Regulator 455 Balanced Regulator Bias Adjustment Field Service with Demand Regulator on Helmet
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 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
455 Balanced Regulator Bias Adjustment Field Service with Demand Regulator on Helmet 455 Balanced Regulator
Slide the clip away from the regulator main tube.
5) Carefully insert the tip of a small flat blade screwdriver into the slot at the top of the lock clip to loosen it and slide the clip away from the regulator main tube.
You must hold the lever down to remove all main components as a sub assembly.
When you pull the flex knob assembly out, the main tube and related parts will follow.
6) Using the 1" open end wrench, loosen the pack-ing nut about 1 turn. Next, while fully depress-ing the lever arm, grasp the flex knob and pull it straight away from the regulator body. This will remove all of the main components of the regula-tor valve mechanism as a single, easy to handle unit.
Separate the flex knob assembly from the main tube.
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 tube. The transfer pin may fall from the end of the shaft. Be careful not to lose it.
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.
9) Remove the lever arm bearing clip.
10) Remove the lever by gently pulling one leg out from the slot on the main tube, followed by the second leg.
Remove the balance spacer, spring and inlet valve assembly from the main tube.
11) Slide the balance spacer, spring, inlet valve assembly out from the main tube.
455 Balanced Regulator Bias Adjustment Field Service with Demand Regulator on Helmet 455 Balanced Regulator
Unscrew the adjustment nipple (turn it “out”) from the main tube. Use the wooden dowel rod to push it
free.
12) Unscrew the adjustment nipple (turn it “out”) from the main tube. Use the wooden dowel rod to push it free. Carefully check the inlet nipple O-ring for damage, even small cuts may cause leaking
13) Inspect all parts for signs of wear or damage and replace if necessary.
14) Clean all parts per "Routine Maintenance" on page FRNT-36. Replace any parts if damage is pres-ent 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®. It is not necessary 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®.
16) Install the O-ring onto the main tube.
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-RINGS. Excess lubrication could possibly collect at the end of this part and block the critical air balancing hole.
18) Spread the arms of the lever just enough to install it onto the main tube.
“WINGS”
AREA FOR LEVER TO FIT INTO TOWARDS BOTTOM OF 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
455 Balanced Regulator 455 Balanced Regulator Bias Adjustment Field Service with Demand Regulator on Helmet
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.
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).
455 Balanced Regulator Bias Adjustment Field Service with Demand Regulator on Helmet 455 Balanced Regulator
Install the transfer pin then install the flex knob assembly about four turns.
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.
Install the bearing clip onto the outside of the main tube.
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.
455 Balanced Regulator 455 Balanced Regulator Bias Adjustment Field Service with Demand Regulator on Helmet
Thread the adjustment nipple into the main tube.
Using a flat blade screwdriver, thread the nipple into the tube slowly.
25) Lightly lubricate the O-ring and insert the adjustment nipple into the main tube on the end opposite end from the adjustment knob. Using a flat blade screwdriver, thread the nipple into the tube slowly.
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 lubricated. Then depress the lever down and carefully install the main tube assembly into the body, and adjustment knob into the regulator, un-til the threaded end of this assembly comes com-pletely through to the opposite side of the regula-tor body. Make sure the HEX flat area aligns to the mating HEX in the regulator body. This will be evident by having the lever arm oriented cor-rectly in relation to the top of the regulator.
NOTE: It is important to do steps 27) and 28) in this sequence.
Details of the 455 Balanced main tube and associated parts.
First27) Install the O-ring and the bent tube adapter and tighten to 30 inch pounds.
Second28) Tighten the packing nut at the flex knob with a one inch wrench to 30 inch pounds. Turn in on the flex knob until an audible click is heard then out three full turns. This is typically very close to optimum adjustment.
29) Check the adjustment of the regulator using recommended air pressure (check lever arm play when pressurized). If you followed the, “tip” not-ed in step 25), the regulator should be very close to correctly adjusted, if not already correctly ad-justed.
30) Install the lock clip on the main tube, rein-stall the diaphragm and cover assembly. Tighten the screws to 15 to 18 inch pounds.
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.
1.1.6 455 Balanced Regulator RemovalRequired Tools:11/16 inch Open-end Attachment on Torque Wrench7/8 inch Open-end Wrench7/8 inch Open-end Attachment on Torque Wrench1 3/8 inch Socket
1/4 inch Flat Blade Attachment on Torque Screw-driverMedium Blade Screwdriver
1) Remove the bent tube assembly, per "1.1.2 Re-moval of the Bent Tube Assembly" on page BNT-1.
Be sure to remove and set aside the whisker spacers.
2) Remove the screws, anodes or kidney plates and whisker spacers from the whiskers.
3) Remove the nose block device per "Nose Block Assembly Removal" on page FCPRT-5.
4) Remove the oral nasal mask per "Oral Nasal Mask Removal" on page ON-1.
5) The regulator mount nut is removed along with the sealing O-ring.
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.
Remove the regulator from the helmet.
7) Now the regulator assembly can be pulled out of the helmet.
Remove the tie wrap.
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 DisassemblyRequired Tools:1" Open end attachment on torque wrench1/4" Flat Blade Attachment on Torque ScrewdriverMINI 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 diaphragm.
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
NOT ATTEMPT TO SEPARATE THE KNOB AND PACKING NUT WITHOUT FIRST RE-MOVING THE ADJUSTMENT SHAFT.
Hold the packing nut while turning the flex knob clockwise. You will notice the internal adjust-ment shaft will travel outward AWAY from the packing nut. It may be easier to place the hex of the packing nut into a vise or pliers, but do not over compress.
This shaft may not fall out, so after about ten full turns of the knob, you may insert a small screw-driver into the outer end of the flex knob and push on the end of the adjustment shaft to allow removal from the packing nut.
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.
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.
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!
Assembly of the 455 Balanced Regulator 455 Balanced Regulator
Remove the exhaust valve insert retainer ring from the regulator body.
8) Remove the exhaust valve insert retainer ring from the regulator body.
Remove the exhaust valve insert assembly.
Remove the sealing O-ring.
9) Remove the exhaust valve assembly and its 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 RegulatorRequired Tools:11/16 inch Open-end Attachment on Torque Wrench 7/8 inch Torque Wrench7/8 inch Open-end Wrench Attachment on Torque Wrench1 1/4 inch Flat Blade Attachment on Torque Screw-driver1/4–3/8 inch Flat Blade Screwdriver
455 Balanced Regulator Assembly of the 455 Balanced Regulator
PACKING NUT
SHAFT O-RING
BEARING WASHER
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® and install into 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.
Installing the Flex Knob3) Begin by lightly lubricating the groove in the end of the flex knob where it presses into the packing nut with Christo-Lube®.
Insert the knob into the packing nut at an angle as shown using your hand or a vise.
Using a wide slotted screwdriver, push the rest of the flex knob into the packing nut.
4) 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
5) 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.
Assembly of 455 Balanced Regulator 455 Balanced Regulator
Christo-Lube® and install into the external O-ring groove of the packing nut.
Push in on the adjustment shaft while turning the flex knob counterclockwise to engage threads
1.1.9 Assembly of 455 Balanced Regulator
The regulator body must be clean and free of foreign matter.
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.
Install the new exhaust valve into the insert. Use care to insure 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. The exhaust valve installs on the side that has the ring support.
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 valve insert must be oriented so that it seals against the O-ring and the exhaust valve will mate properly with the insert.
455 Balanced Regulator Assembly of 455 Balanced Regulator
GAP
FREE END
Install the retainer clip.
5) Install the retainer clip. Use a flat blade screw-driver to push the retainer clip into the opening in the regulator body for the exhaust valve in-sert. The clip should lock into place. Make sure it is pressed into the groove completely. This is ex-tremely important to prevent the exhaust compo-nents from becoming dislodged. The ends of the ring should have a gap between them.
6) Cut off any excess tail from the exhaust valve that protrudes into the regulator body.
To test to see if the insert is installed properly, try to spin the insert. It should be difficult, or not able to
turn.
To test to see if the insert is installed properly, try to spin the insert. It should be difficult, or not able, to turn. You should not be able to dislodge the insert by hand. Friction between the insert,
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 main tube. Lubricate with Christo-Lube®.
7) Install the O-ring on the main tube. Lubricate with Christo-Lube®.
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.
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. Lubricate with Christo-Lube®.
11) See the remainder of the main tube assembly and installation procedure starting on step 17) on page 455BAL-8.
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.
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 InstallationRequired Tools:11/16 inch Open-end Attachment on Torque Wrench 7/8 inch Open-end Wrench Attachment on Torque Wrench7/8 inch Open-end Torque Wrench1 3/8 inch Socket1/4 inch Flat Blade Attachment on Torque Screw-driver
Begin by installing the regulator at an angle, as shown, to the main exhaust body.
1) Install the tie wrap on the center section of the exhaust whisker, (the exhaust main body) and tighten. Remove excess tie wrap.
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.
