Kirby Morgan 455 User manual

© MMXIX Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 190619003 455BAL-1
455 Balanced Regulator 455 Balanced Demand Regulator Test for Correct Adjustment, Fully Assembled
455 Balanced Regulator
Contents
455BAL-1 1.1 General
455BAL-1 1.2 455 Balanced Regulator
Performance
455BAL-1 1.2.1 455 Balanced Demand
Regulator Test for Correct
Adjustment, Fully Assembled
455BAL-2 1.2.2 Adjusting the 455
Balanced Regulator
455BAL-4 1.3 455 Balanced Regulator
Bias Adjustment Field Service
with Demand Regulator on
Helmet
455BAL-13 1.4 455 Balanced Regulator
Removal
455BAL-15 1.5 455 Balanced Disassembly
455BAL-18 1.6 Assembly of the 455
Balanced Regulator
455BAL-18 1.6.2.1 Assembly of the Flex
Knob
455BAL-18 1.6.2.2 Installing the Flex
Knob
455BAL-20 1.6.1 Assembly of 455
Balanced Regulator
455BAL-23 1.6.2 455 Balanced Regulator
Installation
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.
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.
1.2 455 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.
1.2.1 455 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
the latest checklists at www.kirbymorgan.com or
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 ad-
justing the 455 Balanced regulator.
1) Rotate the ex 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.

455BAL-2 © MMXIX Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 190619003
Adjusting the 455 Balanced Regulator 455 Balanced Regulator
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 ow is stable.
NOTE: The regulator may free ow 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 ows, simply covering the air outlet tube
of the regulator inside the mask should stop any
free ow.
6) Push in gently on the cover of the regulator.
There should be ⅛"–¼" free travel in the cover
before gas ow 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 ¼" BEFORE GAS ow is heard, the
demand regulator requires internal adjustment,
per "1.2.2 Adjusting the 455 Balanced Regulator"
on page 455BAL-2.
1.2.2 Adjusting the 455 Balanced
Regulator
Tools required:
• Air Supply, 135/150 psig Through Standard
Scuba Second Stage Hose
• Flat Blade Screwdriver
•  inch Open-End Attachment on Torque
Wrench
• ⅞inch Open-End Attachment on Torque
Wrench
• ⅞inch 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.

© MMXIX Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 190619003 455BAL-3
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
regulator when performing adjustments. The
quickest and easiest way is to use a standard rst
stage SCUBA regulator with a standard second
stage supply hose having a " straight thread
female tting. The female tting 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
⅛and ¼inch of free play in the lever and no gas
ow. Depress the regulator purge cover several
times, ensure a good ow and ensure the lever
play does not change.
5) Turn off the air supply and bleed off the pres-
sure and remove the supply hose to expose the
adjustment nipple. Insert a at 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  turn at a time or less will suf-
ce.
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 ¼ inch wide at 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 of a turn at a time
to adjust the performance of the regulator.
⅛ " – ¼ "
Diagram of maximum lever arm travel.

455BAL-4 © MMXIX Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 190619003
Adjusting the 455 Balanced Regulator 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 ⅛–¼". The regulator
should just begin to free ow if it is properly adjusted.
9) If you are unable to obtain a proper adjustment
with the regulator following this procedure, or a
steady ow 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 in accordance with the torque speci-
cation 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 "1.3.3
Installation of the Bent Tube Assembly" on page
BNT-4.
1.3 455 Balanced Regulator Bias
Adjustment Field Service with
Demand Regulator on Helmet
It is not necessary to remove the regulator from
the helmet to perform eld maintenance. Howev-
er for scheduled overhauls the regulator should
be completely removed from the helmet and dis-
assembled.
Tools and parts required:
Exploded view of 455 Balanced regulator.
FLEX KNOB
WASHER
TRANSFER PIN
BALANCE SPACER
EXHAUST VALVE INSERT
JAM NUT
EXHAUST VALVE
RETAINER RING
INLET VALVE
LEVER
MAIN TUBE
LOCK CLIP
REGULATOR
COVER RETAINER
FRAME
REGULATOR
PURGE COVER
REGULATOR
COVER GUARD
DIAPHRAGM
ADJUSTMENT
SHAFT
ADJUSTMENT
NIPPLE
PACKING NUT
BEARING CLIP
SEAT
O-RING
O-RING
BENT TUBE
ADAPTER
O-RINGS
NOTE: two LP plugs for manufactur-
er’s test purposes only. Do not remove
unless O-rings require replacement.

© MMXIX Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 190619003 455BAL-5
455 Balanced Regulator Adjusting the 455 Balanced Regulator
• ¼inch Flat Blade Screwdriver on Torque
Wrench
• " Open End Attachment on Torque
Wrench
• ⅞" wrench
• ⅞" 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 "1.3.1 Removal of the Bent Tube Assem-
bly" on page BNT-4.
2) Using a ⅞" 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.

455BAL-6 © MMXIX Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 190619003
Adjusting the 455 Balanced Regulator 455 Balanced Regulator
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 at 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.
Slide the clip away from the regulator main tube.
5) Carefully insert the tip of a small at 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.

© MMXIX Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 190619003 455BAL-7
455 Balanced Regulator Adjusting the 455 Balanced Regulator
When you pull the ex knob assembly out, the
main tube and related parts will follow.
6) Using the " open end wrench, loosen the
packing nut about 1 turn. Next, while fully de-
pressing the lever arm, grasp the ex 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 ex knob assembly from the main tube.
The transfer pin may fall from the end of
the shaft. Be careful not to lose it.
7) Unscrew the ex 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 ex 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 ex 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.

455BAL-8 © MMXIX Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 190619003
Adjusting the 455 Balanced Regulator 455 Balanced Regulator
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, and inlet
valve assembly out from the main tube.
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 "1.1 Routine Mainte-
nance" on page IM-1. 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 ex 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.

© MMXIX Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 190619003 455BAL-9
455 Balanced Regulator Adjusting the 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-
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 THE LEVER
FITS INTO
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
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 rst 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 rst 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.

455BAL-10 © MMXIX Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 190619003
Adjusting the 455 Balanced Regulator 455 Balanced Regulator
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.
NOTE: Make sure the balance spacer is properly
aligned inside the main tube by pushing in on the
end of the spacer with your nger tip, to see that
it moves inward (i.e., it engages the hole in the
inlet valve).
23) Lightly lubricate the ends of the transfer pin
and install into the end of the ex knob assembly.
24) With light pressure applied to the transfer
pin with your nger, back out ex knob assembly
all the way and then in about three turns.
NOTE: You should notice the transfer pin travel
forward when turn the ex knob in three turns.
25) Thread the ex knob assembly onto the main
tube until three plus threads are visible. DO
NOT TIGHTEN the Flex knob assembly ALL
THE WAY DOWN on the main tube.
BWARNING
Threading the ex knob assembly all
the way down onto the main tube will
cause incorrect installation and possi-
ble failure which could result in injury
or drowning.
When installing the ex knob assembly it is critical
to leave three plus threads exposed on the main tube.

© MMXIX Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 190619003 455BAL-11
455 Balanced Regulator Adjusting the 455 Balanced Regulator
BALANCED SPACER
INLET VALVE
LEVER ARM
MAIN TUBE
ADJUSTMENT
NIPPLE
BEARING CLIP
SPRING
SEAT
O-RINGS
O-RINGS
Install the bearing clip onto the
outside of the main tube.
26) Install the bearing clip onto the outside of the
main tube.
NOTE: There is a locating pin on the clip that
must engage the correct hole on the main tube.
There are also small recesses on either side that
the legs of the lever arm t into.
The multifaceted side of the bearing clip faces
the hex side of the main tube. The rounded side
faces toward the adjustment knob assembly.
Thread the adjustment nipple into the main tube.
Details of the 455 Balanced main tube and associated parts.

455BAL-12 © MMXIX Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 190619003
Adjusting the 455 Balanced Regulator 455 Balanced Regulator
Using a at blade screwdriver, thread
the nipple into the tube slowly.
27) Lightly lubricate the O-ring and insert the
adjustment nipple into the main tube on the end
opposite the adjustment knob. Using a at 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.
BCAUTION
If the adjustment nipple is screwed
into the main tube too far or until it
can not go further, damage to the
valve seat is possible. Damage to the
seat may cause it to wear out faster
than normal and, in extreme cases,
could cause the adjustable nipple to
seal improperly on the seat resulting
in slight free ow.
28) Make sure the main tube O-ring has been
installed and is lightly lubricated. Then depress
the lever down and carefully install the main
tube assembly into the regulator body with the
lever arm facing toward you so it is visible.
29) Push the main tube completely into the regu-
lator body. Conrm three plus threads are visible
on the inside of the regulator body.
NOTE: It is important to do steps
30) and 31) in this sequence.
First
30) Install the O-ring and the bent tube adapter
and tighten to the torque specications from the
correct Table (by model) in Appendix Contents,
Torque Specs starting on page APNDX-19.
Install the O-ring in the bent tube adapter.
NOTE: A small gap should be visible between
the regulator body and the adjustment packing
nut. If no gap is observed loosen the bent tube
adapter, minimum of 2 revolutions, and unscrew
the large hex nut on the knob assembly, a little
more from the main tube until a visible gap ap-
pears between the hex nut and regulator body.
Repeat the proper sequences to tighten.

© MMXIX Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 190619003 455BAL-13
455 Balanced Regulator Adjusting the 455 Balanced Regulator
Second
31) Tighten the packing nut at the ex knob
with to the torque specications from the cor-
rect Table (by model) in Appendix Contents,
Torque Specs starting on page APNDX-19.
32) Turn in on the ex knob until an audible click
is heard then out three full turns. This is typi-
cally very close to optimum adjustment.
33) 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 27), the regulator should be very close
to correctly adjusted, if not already correctly ad-
justed.
34) Install the lock clip on the main tube, rein-
stall the diaphragm and cover assembly. Tighten
the screws to to the torque specications from the
correct Table (by model) in Appendix Contents,
Torque Specs starting on page APNDX-19.
35) If necessary, adjust the regulator per "1.2.2
Adjusting the 455 Balanced Regulator" on page
455BAL-2.
36) Reinstall the bent tube assembly as per "1.3.3
Installation of the Bent Tube Assembly" on page
BNT-4.
1.4 455 Balanced Regulator
Removal
Tools required:
•  inch Open-End Attachment on Torque
Wrench
• ⅞inch Open-End Wrench
• ⅞inch Open-End Attachment on Torque
Wrench
• 1 ⅜inch Socket
• ¼inch Flat Blade Attachment on Torque
Screwdriver
• Medium Blade Screwdriver
1) Remove the bent tube assembly, per "1.3.1 Re-
moval of the Bent Tube Assembly" on page BNT-4.
Be sure to remove and set aside the whisker spacers.

455BAL-14 © MMXIX Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 190619003
Adjusting the 455 Balanced Regulator 455 Balanced Regulator
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.

© MMXIX Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 190619003 455BAL-15
455 Balanced Regulator Adjusting the 455 Balanced Regulator
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 ange.
1.5 455 Balanced Disassembly
Tools required:
• " Open End Attachment on Torque
Wrench
• ¼" Flat Blade Attachment on Torque Screw-
driver
• Mini Flat Blade Screwdriver
1) Seesteps2)onpage455BAL-5through7)onpage
455BAL-7 for bent tube adapter, regulator cover,
diaphragm, lock clip, main tube and packing nut
removal and inspection instructions for the dia-
phragm.
FLEX KNOB
WASHER
TRANSFER PIN
O-RING
ADJUSTMENT
SHAFT
“BOSS”
ADJUSTMENT
PACKING NUT
455 Balanced ex knob assembly.
The adjustment shaft must be completely
removed to allow the removal of the ex knob.
2) The adjustment shaft must be completely re-
moved to allow the removal of the ex knob. DO

455BAL-16 © MMXIX Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 190619003
Adjusting the 455 Balanced Regulator 455 Balanced Regulator
NOT ATTEMPT TO SEPARATE THE KNOB
AND PACKING NUT WITHOUT FIRST RE-
MOVING THE ADJUSTMENT SHAFT.
Hold the packing nut while turning the ex 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 ex 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
ex knob will make separation and removal
much easier.
With the shaft out, the ex knob can be
separated from the packing nut.
3) With the shaft out, the ex 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 ex 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-8 through 13)
on page 455BAL-8 for lever arm bearing clip,
lever arm, balance spacer, spring, inlet valve as-
sembly and adjustment nipple removal.

© MMXIX Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 190619003 455BAL-17
455 Balanced Regulator Adjusting the 455 Balanced Regulator
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!
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.

455BAL-18 © MMXIX Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 190619003
Adjusting the 455 Balanced Regulator 455 Balanced Regulator
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 "1.3 General Clean-
ing & Inspection Procedures" on page GENPRE-4.
Lubricate O-rings and moving parts with a light
coating of Christo-Lube®.
1.6 Assembly of the 455 Balanced
Regulator
Tools required:
•  inch Open-end Attachment on Torque
Wrench
• ⅞inch Torque Wrench
• ⅞inch Open-end Wrench Attachment on
Torque Wrench
• 1 ¼inch Flat Blade Attachment on Torque
Screwdriver
• ¼–⅜inch Flat Blade Screwdriver
1.6.2.1 Assembly of the Flex Knob
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®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 at.
1.6.2.2 Installing the Flex Knob
1) Begin by lightly lubricating the groove in the
end of the ex 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.

© MMXIX Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 190619003 455BAL-19
455 Balanced Regulator Adjusting the 455 Balanced Regulator
Using a wide slotted screwdriver, push the
rest of the ex 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 ex
knob into the packing nut.
Lubricate threads on adjustment shaft with
Christo-Lube® and insert into ex knob
3) Next, lubricate the threads of the adjustment
shaft with Christo-Lube® and insert into the ex
knob. Push on the adjustment shaft’s end while
turning the ex knob counterclockwise to engage
threads. Continue turning the ex knob counter-
clockwise until the ex knob stops.
S.S.
REGULATOR BODY
EXHAUST VALVE INSERT
RETAINER RING
O-RING
EXHAUST
VALVE
455 Balanced exhaust valve mechanism.

455BAL-20 © MMXIX Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 190619003
Assembly of 455 Balanced Regulator 455 Balanced Regulator
4) Lubricate the larger packing nut O-ring with
Christo-Lube®and install into the external O-
ring groove of the packing nut.
Push in on the adjustment shaft while turning the
ex knob counterclockwise to engage threads
1.6.1 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 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.
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.