455 Balanced Regulator

455 Balanced Regulator General
455 Balanced Regulator

Contents
455BAL-1 1.1 455 Balanced Regulator 455BAL-12 1.1.6 455 Balanced Regu-
455BAL-1 1.1.1 General lator Removal
455BAL-1 1.1.2 455 Balanced Regu- 455BAL-13 1.1.7 455 Balanced Disassembly
lator Performance 455BAL-16 1.1.8 Assembly of the 455
455BAL-1 1.1.3 455 Balanced Demand Balanced Regulator
Regulator Test for Correct Ad- 455BAL-17 1.1.8.1 Assembly of the Flex Knob
justment, Fully Assembled 455BAL-17 1.1.8.2 Installing the Flex Knob
455BAL-2 1.1.4 Adjusting the 455 455BAL-18 1.1.9 Assembly of 455 Bal-
Balanced Regulator anced Regulator
455BAL-4 1.1.5 455 Balanced Regulator Bias 455BAL-21 1.1.10 455 Balanced Regu-
Adjustment Field Service with lator Installation
Demand Regulator on Helmet
1.1 455 Balanced Regulator KMDSI Daily Set Up and Functional Checklist.
See the Kirby Morgan® or Dive Lab websites for
1.1.1 General the latest checklists at www.kirbymorgan.com or
www.divelab.com.
The 455 Balanced Regulator is an ultra-high per-
formance regulator, continuing the long line of
Check the regulator for adjustment and proper
exceptional regulators from Kirby Morgan®. Its
function with the assembly complete, and sup-
construction and materials make it an extremely
plied with a breathing gas supply pressure of be-
rugged regulator.
tween 135 to 150 p.s.i.g
NOTE: When storing the helmet for any length
NOTE: 135 to 150 p.s.i.g. over ambient is the
of time, ensure that the Flex Knob, for adjusting
standard supply pressure to be used when
the regulator, is turned “out” fully counterclock-
adjusting the 455 Balanced regulator.
wise to avoid stressing the bias springs. This will
prolong the life of both the inlet valve, seat, and
1) Rotate the flex knob in, clockwise towards the
bias spring.
regulator body, until a clicking can be heard with
each full turn of the knob. This is an audible indi-
1.1.2 455 Balanced Regulator cation the tension of the bias adjustment spring
Performance is as tight as it will get. The adjustment knob will
The 455 Balanced Regulator is an all stainless never bottom out or stop turning in this direction
steel regulator of a balanced design that offers and no damage to the mechanism will occur. The
far greater overall breathing performance than clicking is an audible indication the adjustment
the non-balanced SuperFlow® and SuperFlow® knob is fully positioned. Listen carefully for this
350 regulator. indicating click.
1.1.3 455 Balanced Demand Regulator 2) Ensure the supply pressure is connected and
Test for Correct Adjustment, Fully properly adjusted to 135 to 150 p.s.i.g.
Assembled
3) Turn on the gas supply.
To maintain optimum performance of the de-
mand regulator, it should be checked for proper 4) Rotate the Flex Knob out counterclock-
function and adjustment prior to commencement wise slowly, three full turns.
of diving each diving day, in accordance with the
© MMXVI Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 161209001 455BAL-1

Adjusting the 455 Balanced Regulator 455 Balanced Regulator
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
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
Remove the bent tube and the bent tube adapter.
7/8 inch Open-end Wrench
1) Remove the bent tube assembly from the hel-
met.
Remove the bent tube adapter
2) Remove the bent tube adapter.
455BAL-2 © MMXVI Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 161209001
455 Balanced Regulator Adjusting the 455 Balanced Regulator
3) Attach L.P. supply to the regulator (std. SCU-

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

Adjustment Field Service with Demand
Regulator on Helmet
Before you reinstall the bent tube, connect the low It is not necessary to remove the regulator from
pressure hose to the regulator and pressurize it again. the helmet to perform field maintenance. Howev-
Push in on the regulator cover 1/8–1/4". The regulator er for scheduled overhauls the regulator should
should just begin to free flow if it is properly adjusted. be completely removed from the helmet and dis-
assembled.
9) If you are unable to obtain a proper adjustment
with the regulator following this procedure, or a Tools and Parts Required:
steady flow of gas seems to be leaking, you will 1/4 inch Flat Blade Screwdriver on Torque Wrench
need to disassemble the regulator to check the 15/16" Open End Attachment on Torque Wrench
condition of the lever and possibly for a damaged 7/8" wrench
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.
455 Balanced Regulator 455 Balanced Regulator Bias Adjustment Field Service with Demand Regulator on Helmet
7/8" torque wrench from the main body of the regulator to expose the
Balance Spacer, P/N 550-549 with two O-rings , interior parts.
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.
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.
Loosen the screws and washers on

either side of the cover.
Carefully insert the tip of a small flat blade
3) Loosen the four screws and washers on either screwdriver into the slot at the top of the lock clip to
side of the regulator cover. These four screws loosen it.
should NOT be removed from the cover assem-
bly. The cover assembly is designed to retain the Note: The two holes for the LP plugs seen on
screws to prevent loss. Un-thread the screws only the right side of the 455 regulator body in the
enough to allow the cover assembly to separate photo above are for manufacturer’s test purposes
only. These two plugs should be left in place
unless the O-rings require replacement.

Slide the clip away from the regulator main tube. When you pull the flex knob assembly out, the
main tube and related parts will follow.
5) Carefully insert the tip of a small flat blade
screwdriver into the slot at the top of the lock 6) Using the 15/16" open end wrench, loosen the
clip to loosen it and slide the clip away from the packing nut about 1 turn. Next, while fully de-
regulator main tube. pressing 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 regulator 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.
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.

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 the RINGS. Excess lubrication could possibly collect
main tube. Use the wooden dowel rod to push it free. at the end of this part and block the critical air
balancing hole.
12) Unscrew the adjustment nipple (turn it “out”)
from the main tube. Use the wooden dowel rod 18) Spread the arms of the lever just enough to
to push it free. Carefully check the inlet nipple install it onto the main tube.
O-ring for damage, even small cuts may cause
leaking
AREA THE LEVER
13) Inspect all parts for signs of wear or damage
and replace if necessary.
FITS INTO, TOWARDS
BOTTOM OF TUBE
14) Clean all parts per "Routine Maintenance"
on page INTRO-38. 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-
essary to disassemble the flex knob assembly.
“WINGS”
15) Install the O-ring onto the adjustment nipple
if you have not already done so. Be sure that the Close-up detail of the inlet valve.
O-ring has been properly lubricated with Chris-
to-Lube® or other lubricants noted in step 14). 19) Study the features of the inlet valve assem-
bly. There are four “wings” towards one end of
16) Install the O-ring onto the main tube. 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
be inserted into the main tube with these walls

toward the bottom of the regulator tube.
While holding the inlet valve in position,

pinch each arm of the lever and slowly
remove the balance spacer and O-rings.
Using the balance spacer with the two
O-rings installed, insert the first O-ring 21) While holding the inlet valve in position,
into the open end of the inlet valve.
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.
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 Install the spring and balance spacer
open end of the inlet valve stainless steel tube with O-ring into the main tube.
and stop at the second O-ring. Now align and in-
sert the inlet valve into the main tube, as noted 22) Install the spring and balance spacer with
above. If this is done properly, the lever should O-ring into the main tube. Make sure the bal-
lift up. If it does not, the valve has not been in- ance spacer is properly aligned inside the main
serted correctly. 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).

Install the transfer pin then install the Install the bearing clip onto the
flex knob assembly about four turns. outside of the main tube.
23) Lightly lubricate the ends of the transfer pin 24) Install the bearing clip onto the outside of
and install into the end of the balance spacer. the main tube. Note that there is a locating pin
Thread the flex knob assembly onto the end of on the clip that must engage the correct hole on
the main tube (closest to the lever arms) until it the main tube. There are also small recesses on
just stops. Hand tighten the assembly and then either side that the legs of the lever arm fit into.
back the assembly out three turns.
The clip is correctly positioned when it is in the
position shown. The square opening on the main
tube must be exposed.
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.
455 Balanced Regulator Removal 455 Balanced Regulator
1.1.6 455 Balanced Regulator Removal

Required Tools:
7/8 inch Open-end 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

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

of the helmet.
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
455 Balanced Regulator 455 Balanced Disassembly
Remove the two O-rings from the balance spacer.
6) Remove the two O-rings from the balance

spacer.
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. Remove the O-ring from the main tube.
7) Remove the O-ring from the main tube.

5) See steps 9) on page 455BAL-7 through 13)
on page 455BAL-8 for lever arm bearing clip, NOTE: Check the condition of this O-ring very
lever arm, balance spacer, spring, inlet valve as- carefully. If there are any signs of damage, it
sembly and adjustment nipple removal. 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. 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"onpageINTRO-44.LubricateO-ringsandmov-
ing parts with a light coating of Christo-Lube®.
1.1.8 Assembly of the 455 Balanced

Regulator
Required Tools:
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
455 Balanced Regulator Assembly of the 455 Balanced Regulator
1.1.8.1 Assembly of the Flex Knob
PACKING NUT
BEARING WASHER
SHAFT O-RING
Using a wide slotted screwdriver, push the
Install the larger O-ring over external rest of the flex knob into the packing nut.
packing nut groove and the smaller O-ring
into internal packing nut groove
2) Place the packing nut into a vise, or by hand,
insert the knob into the packing nut at an angle
1) Lubricate the smaller, shaft O-ring with Chris-
as shown. Twisting the knob may allow the rub-
to-Lube® or equivalent oxygen compatible lubri-
ber to insert further into the packing nut. While
cant, and install into the internal O-ring groove
holding the knob in this position, and using a
of packing nut.
wide slotted screwdriver, push the rest of the flex
knob into the 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.
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-
Insert the knob into the packing nut at an clockwise until the flex knob stops.
angle as shown using your hand or a vise.
4) Lubricate the larger packing nut O-ring with
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
valve insert must be oriented so that it seals
The regulator body must be clean against the O-ring and the exhaust valve will
and free of foreign matter. 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.
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
in the regulator body for the exhaust valve in- properly, try to 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.
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 Christo-Lube®.
Lubricate with 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.
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:
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.

455 Balanced Regulator Installation 455 Balanced Regulator
Install the tie wrap on the regulator. Insert the tube on the exhaust main body
onto the tube of the helmet pod.
Remove excess tie wrap.

Seal with a tie wrap.
1) Install the tie wrap on the center section of
the exhaust whisker, (the exhaust main body) 2) Insert the tube on the exhaust main body onto
and tighten. Remove excess tie wrap. 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 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
Install the O-ring that mounts on the starting on page APNDX-19.
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-

455 Balanced Regulator

Uploaded by

Copyright:

Available Formats

455 Balanced Regulator

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

455 Balanced Regulator

Uploaded by

Copyright:

Available Formats

455 Balanced Regulator General

455 Balanced Regulator

5) Lightly depress the regulator purge cover sev-

NOTE: The regulator may free flow when purged

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

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

1.1.4 Adjusting the 455 Balanced

Remove the bent tube adapter

2) Remove the bent tube adapter.

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

Diagram of maximum lever arm travel.

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

7) If adjustment is necessary, turn off the air

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

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

10) Once the regulator is properly adjusted, rein-

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

1.1.5 455 Balanced Regulator Bias

NOTE: two LP plugs for manufactur-

1) Remove the bent tube assembly from the hel-

2) Using a 7/8" wrench, remove the bent tube

Remove the diaphragm and inspect it carefully.

4) Remove the cover assembly and diaphragm.

Loosen the screws and washers on

Separate the flex knob assembly from the main tube.

You must hold the lever down to remove all

The transfer pin may fall from the end of

7) Unscrew the flex knob assembly from the main

10) Remove the lever by gently pulling one leg

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

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

Remove the balance spacer, spring and inlet

11) Slide the balance spacer, spring, and inlet

Do not over lubricate the O-rings

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

NOTE: The wings that align with the lever arm

be inserted into the main tube with these walls

While holding the inlet valve in position,

20) Using the balance spacer with the two O-

25) Lightly lubricate the O-ring and insert the

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

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

NOTE: It is important to do steps 27) and

Using a flat blade screwdriver, thread

1.1.6 455 Balanced Regulator Removal

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

Install the O-ring in the bent tube adapter.

29) Check the adjustment of the regulator using

32) Reinstall the bent tube assembly as per "1.1.4

Remove the tie wrap.

Cut the tie wrap that connects the regulator body

6) Cut the tie wrap that connects the regulator

Separate the regulator from the Quad

8) The center section of the exhaust whisker,

1.1.7 455 Balanced Disassembly

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

7) Now the regulator assembly can be pulled out

NOT ATTEMPT TO SEPARATE THE KNOB

With the shaft out, the flex knob can be

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

455 Balanced Regulator General