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Dive Gear Express DGX Gears D6 First Stage Service Manual

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DGX Gears D6
First Stage Service Manual

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Summary of Contents for Dive Gear Express DGX Gears D6

  • Page 1 DGX Gears D6 First Stage Service Manual...
  • Page 2 Copyright © 2021 Dive Gear Express All Rights Reserved Revision 1 Published 2/19/2021...
  • Page 3 Improper service of dive equipment can lead to severe injury or death. Dive Gear Express recommends that non-qualified individuals seek professional training/mentoring before attempting repairs or servicing on any diving equipment.
  • Page 4 Cleaning and Rinsing - General Considerations (11) Cleaning and rinsing of the components should be done using clean, fresh water. If available, distilled water is recommended to maintain oxygen cleanliness. (12) Only use degreasers that leave no organic residue (e.g. Simple Green Free & Clear, Blue Gold Cleaner, or any clear liquid dish soap that does not contain scents or dyes).

  • Page 5: Inspection After Cleaning

    Inspection After Cleaning (21) Before assembling the regulator, it is necessary to inspect all the cleaned components. Using the magnifying glass, ensure all parts are clean and contaminate-free, and check the components for damage that may have been hidden by corrosion or lubricant. Look for scratches that may affect the sealing of the regulator.
  • Page 6 This involves using a small clean plastic bag containing a small amount of lubricant. The O-ring is inserted into the bag, worked around to evenly coat with lube while squeezing off excess, then taken out of the bag and used in its location – Fig. 2. Fig.

  • Page 7: Tool List

    2. Tool List (1) The tool list has been divided into two sections. Required and Recommended. Required tools are necessary for servicing the regulator. Recommended are those items that make servicing easier or more efficient and lessen the chance of damage. Required Tools –...
  • Page 8 (3) The First Stage Body Holding Tool, In-Line Adjusting Tool with IP Gauge, Spanner Wrench, Brass O- Ring Pick Set, and IP Gauge can be found at Dive Gear Express using the link below. https://www.divegearexpress.com/tools/scuba-tools...
  • Page 9 (4) Additional useful items are nitrile gloves and, to aid in rinsing, a plastic colander – Fig. 5, and small mesh strainers for smaller parts – Fig. 6. Fig. 5 Fig. 6...
  • Page 10 3. Preliminary Testing (1) Preliminary testing of the regulator is necessary to identify any issues with the first and second stages and verify the overall regulator function. This testing will include: Visual inspection of the first and second stages Inspection of the hoses Intermediate Pressure (IP) check Cracking pressure and second stage negative pressure test Visual inspection is done to identify issues that could affect servicing and to ensure that pressurizing...
  • Page 11 Caution Note: If the second stage is leaking even slightly, IP will be affected. If it is leaking, turn the adjustment knob to stop the flow or use a second stage that is not leaking when paired with the first stage. It is a clear indication that the second stage requires rebuilding if turning the adjustment knob does not stop the flow.

  • Page 12: First Stage Disassembly

    4. First Stage Disassembly (1) Ensure the system is depressurized. Document the position of all hoses and port plugs. The use of small, clean containers to hold parts is recommended. (2) In the following steps, the part numbers from the schematic will be used with their description. The numbers on the photos also correspond with the parts list on the schematic.
  • Page 13 3. Secure the regulator in a vise using the first stage handle with the DIN assembly facing up - Fig. 10. Remove the DIN Retainer (03) using a 6mm Hex – Fig. 11. Fig. 10 Fig. 11 4. Lift the DIN Wheel (07) off the DIN Housing (08) - Fig. 12. Loosen and remove the DIN Housing using a 19mm deep socket or open-end wrench –...
  • Page 14 5. Unscrew the Adjustment Screw (19) until no spring pressure is felt with the 6mm hex – Fig. 15. Three to four turns is sufficient. Do not remove the screw. With the first stage handle in one of the high- pressure ports, and a pin spanner, loosen the Diaphragm Cap (18) by applying firm, even downward pressure.
  • Page 15 The Diaphragm Cap assembly consists of the Cap (18), the Spring Seat (15), Spring Washers (16*), Main Spring (17), and Adjust Screw (19) – Fig. 20. Fig. 20 7. Turn the Main Housing (11) upright as shown to expose the Diaphragm (13*) and Diaphragm Washer (14*) –...
  • Page 16 9. Secure the first stage handle in the vise with the Turret (24) facing up and insert the 6mm hex into it, making sure that it is firmly seated and straight. Failure to firmly seat the hex may damage the sides of Turret Bolt (30) –...
  • Page 17 11. Set the Main Housing aside and carefully remove the HP Seat (25*). Pull the Valve Spring (26) off the Turret Bolt. Remove the Thrust Washer (28*) and O-ring (29*). Using the pinch method or brass/nylon pick, remove the O-ring (04*) – Fig. 27 and 28. Fig.
  • Page 18 13. Remove the Turret (24) from the regulator Main Housing – Fig. 31. Remove the O-ring (23*) from the Main Housing. Note that the O-ring may come off with the Turret – Fig. 32. Fig. 31 Fig. 32 14. Carefully inspect the machined orifice in the Main Housing. It should show no evidence of nicks or uneven surfaces on the bevels - Fig.
  • Page 19 (3) The photographs below show the disassembled first stage – Fig. 34 and the items in the Service Parts Kit – Fig. 35. The parts not in the service kit need to be washed, rinsed and dried, as discussed previously. Fig.
  • Page 20 5. First Stage Assembly (1) Before starting the first stage assembly, complete a thorough inspection of all parts to be reused. Refer to the Overview Inspection section for details. At this time, open the service kit and lay out the parts.
  • Page 21 3. The Diaphragm Cap (18), Adjust Screw (19), Spring Seat (15), Washers (16*), and Main Spring (17) will be assembled in the order shown in Fig. 40. Fig. 40 4. Turn the Adjust Screw (19) into the Diaphram Cap (18) until 3 to 4 threads are showing as illustrated –...
  • Page 22 5. Tighten the Diaphragm Cap assembly onto the Main Housing using the pin spanner – Fig. 43. There should be no gap between the Main Housing and the Cap. The connection is tight when pressure is applied using the spanner, and no movement is observed. Fig.
  • Page 23 7. Set the Turret Bolt (30) on a flat surface. Using the Tribolube syringe, apply a small amount of lube to the O-ring seating area. Install the O-ring (27*) using a dowel to push it into place and seat – Fig. 46. Place O-ring (29*) on the Turret Bolt, followed by the Thrust Washer (28*).
  • Page 24 9. Install the Turret Bolt assembly (25*-30 and 04*) into the Main Housing – Fig. 50. This is done by holding the Housing vertical and the Turret Bolt assembly on the hex socket. Insert the assembly up into the housing and turn until the threads are engaged. Continue to turn the Turret Bolt assembly until it is seated.
  • Page 25 11. Turn the first stage handle so that the DIN inlet is facing up. Place the Saddle (10) on the inlet. Install the O-ring (09*) at the end of the DIN Housing (08) – Fig. 53. A tiny amount of lube – only enough to result in a slight sheen - to prevent the O-ring from seizing and being damaged can be applied.
  • Page 26 Caution Note: Torquing the DIN Housing and DIN Retainer connections to different values reduces the housing's risk of becoming loose or the retainer and housing to be seized. This can occur when the regulator is pressurized and then rotated on the tank valve to orient it, usually for hose routing. Subsequently, a diver may notice the loose retainer and grab a hex to snug it up.
  • Page 27 First Stage Torque Specifications (2) For a successful rebuild, it is necessary to use proper torque on all connections that require it. The following specifications should be used, listed in the order they occur in the assembly: Turret Bolt (30) to Main Housing (11) 170 in lbs/200 kgf cm/19 Nm DIN Housing (08) to Main Housing (11) 230 in lbs/260 kgf cm/26 Nm...
  • Page 28 You will need to move the regulator between the cylinders, and each time it is pressurized, be sure to have the purge button depressed slightly and allow the supply pressure to come up with this safety measure used. A transfill whip like the one from Dive Gear Express will make setting up the cylinders easier.
  • Page 29 (8) Finally, take the first stage with the second stage and LP inflator hose and place it on a cylinder that can be submerged in water. Submerge the first stage and check for any leaks between the Main Housing and Turret, DIN connection, port plugs, and hose connections. If none are present, the first stage service and testing are complete.
  • Page 30 (9) General Trouble Shooting – Not all possibilities may be noted. No airflow Check supply pressure Free flowing Excessive IP; HP Seat bad, Orifice edge compromised or damaged Excessive IP Bad HP Seat, HP Seat assembly O-ring(s) bad Leaks between seams on Main Housing Bad O-rings;...