Kirby Morgan 455 User manual

Kirby Morgan®
455 Balanced Regulator Installation Guide
KMDSI Part #100-204
Patented, patents pending, foreign patents apply
TM
Kirby Morgan Dive Systems, Inc.
1430 Jason Way
Santa Maria, CA 93455, USA
Telephone [phone], FAX [phone]
E-Mail: [e-mail], Web Site:www.KirbyMorgan.com
BWARNING
Diving with compressed breathing gas is a hazardous activity. Even if you do every-
thing right there is always the danger that you may be killed or injured. No piece of
diving equipment can prevent the possibility that you may be killed or injured any time
you enter the water.
The 455 balanced regulator meets or exceeds all performance and testing requirements of all
government and non-government testing agencies throughout the world. Only Kirby Mor-
gan masks and helmets have achieved the Dive Lab®, CR (Commercial Rated) mark.
Kirby Morgan, SuperLite®, BandMask, Band Mask, KMB, KMB-Band Mask, DSI, Diving Systems In-
ternational, EXO, REX®, SuperFlow®and DECA are all registered trademarks of Kirby Morgan Dive
Systems, Inc. Use of these terms to describe products that are not manufactured by KMDSI is
illegal.
The two dimensional images (such as photographs and illustrations) of our products are © copyrighted
and trademarks of Kirby Morgan Dive Systems, Inc. The three dimensional forms of our products are
trademark, trade design and trade dress protected.
© MMXV Kirby Morgan Dive Systems, Inc. All rights reserved. This manual is made available for the
express use of the owner of this Kirby Morgan product. No part of this manual may be reproduced,
stored in any retrieval system, or transmitted, or used in any form or by any means, whether graphic,
electronic, mechanical, photocopy, or otherwise by technology known or unknown, without the prior
written permission of Kirby Morgan Dive Systems, Inc.

INSTL-2 © MMXV Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 150205001
Removal of the SuperFlow® 350 Regulator 455 Balanced Regulator Installation Guide
NOTE: to simplify the content of this procedure,
only the stainless steel helmet is referenced.
The following instruction is valid for the follow-
ing products:
SL17C
SL27
KM37
1.1 Removal of the SuperFlow®
350 Regulator
Tools Required:
 inch Open-end Wrench
Tools Required:
 open end wrench
2 ea. ⅞wrenches
1.1.1 Removal of the Bent Tube
1) Always start removal at the side block end.
Loosen the tube with the  inch wrench. The
free swiveling mount nut on this end of the bent
tube can be un-threaded completely and can slide
down the tube.
Always start removal at the side block end.
2) Loosen the lower bent tube nut by using the
two ⅞inch wrenches. Place one wrench on the
bent tube mount nut and the second on the reg-
ulator inlet jam nut. Only turn the outer nut on
the bent tube to loosen the bent tube.
The bent tube mount nut can then be rotated un-
til free of the regulator inlet nipple tube threads.
3) With the two mount nuts free; the bent tube
assembly can be pulled straight out of the reg-
ulator inlet nipple. The bent tube assembly can
be rotated back and forth to aid removal, if nec-
essary.
CONTENTS
INSTL-2 1.1 Removal of the SuperFlow®350 Regulator
INSTL-2 1.1.1 Removal of the Bent Tube
INSTL-3 1.1.2 SuperFlow®350 Removal from Helmet/Mask
INSTL-3 1.1.3 Nose Block Device Removal
INSTL-3 1.1.4 Oral Nasal Mask and Microphone Removal
INSTL-3 1.1.5 Regulator Mount Nut Removal and Separation of the SuperFlow®350 from the
Helmet/Mask
INSTL-4 1.2 Installation of the 455 Balanced Regulator
INSTL-4 1.2.1 Re-installation of the Bent Tube Assembly
INSTL-5 1.2.2 Oral Nasal Mask and Microphone Installation
INSTL-5 1.2.3 Nose Block Device Replacement

© MMXV Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 150205001 INSTL-3
455 Balanced Regulator Installation Guide Removal of the SuperFlow® 350 Regulator
Removing the bent tube.
4) Cut the tie wrap that holds the regulator on
the Quad-Valve extension of the pod.
1.1.2 SuperFlow®350 Removal from
Helmet/Mask
1) Remove the screws that secure the whisker to
the port. Take care not to lose the zinc anodes, if
so equipped, screws, whisker spacers or kidney
plates if present.
Take care not to lose the whisker spacers.
1.1.3 Nose Block Device Removal
BCAUTION
The nose block device MUST be re-
moved and reinstalled when installing
a new oral nasal mask. Simply stretch-
ing the oral nasal mask over the nose
block device can cause the oral nasal
mask to tear.
1) Remove the nose block device rst.
2) Hold the nose block knob with a pair of pli-
ers padded by a cloth, while unscrewing the nose
block device with your hand.
3) After the knob is removed, loosen and remove
the packing nut.
4) Slip the two o-rings off the end of the shaft of
the nose block device and slide the nose block de-
vice out through the oral nasal mask.
1.1.4 Oral Nasal Mask and Microphone
Removal
1) Remove the microphone.
2) Once the microphone has been removed and
steps 1–4 above are done, the oral nasal mask
can now be pulled off the regulator mount nut. It
is held on by a snap t.
1.1.5 Regulator Mount Nut Removal and
Separation of the SuperFlow®350 from
the Helmet/Mask
1) Loosen the regulator mount nut. Cut the tie
wrap sealing the whisker main body to the wa-
ter dump/exhaust outlet on the pod/water dump
adapter cover.

INSTL-4 © MMXV Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 150205001
Installation of the 455 Balanced Regulator 455 Balanced Regulator Installation Guide
Removal of the regulator mount nut.
2) Pull the regulator body/whisker away from the
helmet.
3) Cut the tie wrap that secures the whisker as-
sembly to the regulator body and remove. Inspect
this assembly and replace parts as needed
1.2 Installation of the 455
Balanced Regulator
1) Install the mount tube of the 455 regulator
into the opening of the pod.
2) Line up the quad valve opening on the quad
main exhaust body attached to the 455 regulator,
with the quad valve extension on the pod, and
install.
3) Install the tie wrap around the quad main ex-
haust body and tighten. Cut and remove excess
tie wrap.
1.2.1 Re-installation of the Bent Tube
Assembly
Tools Required:
Regulator Mount Nut Socket
 inch Open-end Torque Wrench Attachment
Torque wrench
2 ea. ⅞inch regulator adjustment wrenches
Normal minimum replacement parts during
overhaul: O-ring, Teon®
Inspect rubber O-ring and replace if damaged.
1) Lightly lubricate the bent tube O-ring and in-
stall into the O-ring groove at the regulator end
of the bent tube, then install a new Teon®O-ring
at the side block end.

© MMXV Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 150205001 INSTL-5
455 Balanced Regulator Installation Guide Installation of the 455 Balanced Regulator
2) Push the O-ring end of the bent tube assembly
into the regulator nipple tube. Slide it in until
the side block end is aligned with the threads for
the mount nut.
3) Be sure the new Teon®O-ring is in place on
the side block end of the bent tube, then engage
the threads to the side block and hand tighten.
4) Start the “regulator to bent tube” mount nut
onto the nipple tube of the demand regulator and
run it up by hand as far as it will go and hand
tighten.
5) Using a torque wrench, tighten the bent tube
assembly nut onto the side block and tighten 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.
6) Install regulator mount tube sealing O-ring
all the way. Install regulator mount nut, mak-
ing sure orientation is correct. Using a torque
wrench tighten in accordance with the torque
specication found in the correct Table (cor-
rect model) of the manual Appendix. See Ap-
pendix Contents: Torque Specs starting on
page APNDX-19.
7) Make certain the regulator end of the bent
tube is threaded onto the regulator (nipple tube)
far enough, by lightly applying torque to the hex
nut on that end. When a small amount of resis-
tance is felt, lock it into place with the jam nut.
Tighten the bent tube to the proper torque value.
8) Hold the hex on the bent tube with a wrench
and tighten the jam nut against it with a torque
wrench. See “Torque Specs” on page APNDX-19
for correct torque.
1.2.2 Oral Nasal Mask and Microphone
Installation
1) Snap the oral nasal over the regulator mount
nut. Take extra care to make sure the mask has
snapped into position all the way around the
mount nut.
2) Reinstall the microphone.
1.2.3 Nose Block Device Replacement
1) Prior to reassembly, lubricate the two o-rings.
2) Slide the shaft through oral nasal mask in the
helmet or mask shell.
Install the nose block
device through the interior
of the oral nasal mask.
3) Place both o-rings on the shaft, followed by the
packing nut and the knob.
4) Tighten the packing nut until snug. Do not

INSTL-6 © MMXV Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 150205001
Installation of the 455 Balanced Regulator 455 Balanced Regulator Installation Guide
over tighten, as this will make it difcult to slide
the nose block device in and out.
5) Tighten the knob with the pliers, padded by
a cloth, while holding the padded end with your
hand.
Properly installed nose block device.
6) Reinstallwhiskers,zincanodesorkidneyplates,
spacers and screws and tighten 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.
7) Test the regulator for proper function.
NOTE: When checking the regulator by de-
pressing the purge button, the regulator may
free ow without back pressure inside of the
oral nasal. This is completely normal. Placing
a nger or hand over the outlet tube of the reg-
ulator will prevent free ow. See “1.1.4 Adjust-
ingthe455BalancedRegulator”onpage455BAL-2
in module 455 Balanced Regulator for proper ad-
justment.
NOTE: For all maintenance and adjustment
procedures, refer to the 455 Balanced Regu-
lator module found in the “Manuals and Ex-
ploded Views” link under the “Support” link at
www.kirbymorgan.com.

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TM
Kirby Morgan Dive Systems, Inc.
1430 Jason Way
Santa Maria, CA 93455, USA
Telephone [phone], FAX [phone]
E-Mail: [email protected], Web Site:www.KirbyMorgan.com