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Dive Gear Express DGX Gears FIRST First Stage Service Manual
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Dive Gear Express DGX Gears FIRST First Stage Service Manual

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DGX Gears FIRST
First Stage Service Manual

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Summary of Contents for Dive Gear Express DGX Gears FIRST

  • Page 1 DGX Gears FIRST First Stage Service Manual...
  • Page 2 Copyright © 2020 Dive Gear Express All Rights Reserved Revision 4a Published 10/7/2020 Revision Date Changes 10/7/2020 Initial publication 3/31/2021 Added text to 5. Regulator First Stage Assembly (1).
  • 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 It also helps to keep those parts clean and free of debris that will cling to the lubricant. Caution Note: The DGX Gears FIRST Regulator flow-through piston first stage is primarily intended for use in inflation and light scuba applications such as oxygen decompression.
  • Page 7 Caution Note: The OPV rebuild should be considered a temporary fix to a bubbling valve. Ideally, when the regulator is serviced, the OPV should be replaced. https://www.divegearexpress.com/ over-pressure-relief-valve-user-adjustable...
  • Page 8 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 tools that make servicing easier or more efficient, as well as lessening the chance of damage. Required Tools –...
  • Page 9 Fig. 4 (2) The First Stage Body Holding Tool, Pin Spanner, IP Gauge and Brass O-Ring Pick Set can be found at Dive Gear Express using the link below. https://www.divegearexpress.com/tools/scuba-tools (3) Tools may also be purchased from Scuba Tools at the link below.
  • Page 10 (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 11 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 12 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 13: First Stage Disassembly

    4. First Stage Disassembly (1) Ensure the system is depressurized. Document the position of all hoses, port plugs and the Over Pressure Valve (OPV). 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 14 3. Attach the First Stage Body Holding Tool to the regulator and secure the tool in a vise, DIN side up – Fig.10. In this orientation, you will remove the DIN Retainer (B2) and the DIN Knob (B4). Fig. 10 4.
  • Page 15 5. Remove the O- ring (B8*) from the DIN Housing, the DIN Retainer O-rings (B1*, B3*), and remove the DIN Filter and its O-ring (B6*) from the DIN Housing – Fig. 13. Fig. 13 6. Remove the holding tool from the vise and, using a 1.5 inch or adjustable pin spanner, loosen the Lower Body (21) from the Upper Body (14) - Fig.
  • Page 16 7. Once it has been loosened, unscrew the two parts until a gap is seen. Be aware that there is significant spring pressure between the two parts – Fig. 15. Fig. 15 8. Unscrew the Upper and Lower Bodies to reveal the Spring (16), Piston (19), and Washers (15). Note that one Washer is under the Spring –...
  • Page 17 9. Lift the Washer (15), Piston (19), Spring (16), and Washer (15) from the Body (21) – Fig. 17. Fig. 17 10. Using the blunt straight pick, push the HP seat (17*) from the end of the piston. Then using the pinch method, remove the O-rings (18*, 20*) from the Piston –...
  • Page 18 11. This step is optional. Ideally, when the regulator is serviced, the OPV should be replaced. However, if the OPV is not to be replaced, unscrew the Spring Holder (O8) from the OPV Body (O7) using a 3mm hex. Remove the O-ring (11) and take the Spring (O9) and Bullet (OP10) out of the Body. Carefully separate the Bullet from the Spring.
  • Page 19 (3) The photographs below show the disassembled first stage – Fig. 21 and First Stage Service Parts Kit – Fig. 22. All the parts not in the service kit need to be washed, rinsed and dried, as discussed previously. O-rings and washers that will be replaced with new from the service kit should be discarded. Fig.
  • Page 20 5. Regulator First Stage Assembly (1) Before starting the assembly of the second stage, 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 2. Next, lubricate and install the O-ring (18*) on the Piston, being careful to not damage it on the edge of the Piston - Fig. 24. Ensure the O-ring is seated in the groove – Fig. 25. Fig. 24 Fig. 25 3.
  • Page 22 4. Install the Plastic Cap (22) on the Lower Body – Fig. 28. Fig. 28 5. Place the assembled Piston into the Lower Body, making sure not to damage the O-ring (20*) – Fig.29. Fig. 29...
  • Page 23 6. Stack the Washer (15), Spring (16), and Washer (15) on the Piston -Figs. 30 and 31. Fig. 30 Fig. 31 7. With the Lower Body and Piston assembly held firmly on a flat surface, screw the Upper Body (14) onto the assembly.
  • Page 24 8. Screw the Upper Body onto the assembly so that the threads are firmly engaged and install the first stage handle into one of the ports – Fig. 33. Tighten the parts together by hand until no gap is seen – Fig.
  • Page 25 10. Install the O-ring (B6*) onto the Filter (B5*) as shown – Fig. 36. Insert the Filter into the DIN Housing (B7) – Fig. 37. Place the O-ring (B8*) on the DIN housing – Fig. 38. Fig. 36 Fig. 37 Fig.
  • Page 26 12. Place the O-ring (B3*) on the DIN Retainer (B2) and the O-ring (B1*) into its groove – Fig. 41. Place the DIN Knob on the DIN Housing. Screw the DIN Retainer into the DIN Housing – Fig. 42. Fig. 41 Fig.
  • Page 27 Loosening of the DIN Retainer is most often caused by pressurizing the regulator on a cylinder and then trying to orient the regulator for desired hose routing. Only orient the regulator when the cylinder valve is off and pressure bled from the first stage. 14.
  • Page 28 Caution Note: Failure to properly calibrate the OPV may result in a loss of gas or damage to the inflator mechanism on the device being used (BCD, Drysuit, etc.). It is recommended to only rebuild the OPV if absolutely necessary. It should be replaced at annual service.
  • Page 29 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: DIN Housing (B7) to Upper Body (14) 260 in lbs/300 kgf cm/30 Nm DIN Retainer (B2) to DIN Housing (B7) 150 in lbs/170 kgf cm/17 Nm...
  • Page 30 PSI levels. 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 31 (7)General Trouble Shooting – Not all possibilities may be noted. No airflow Check supply pressure Free Flowing Excessive IP; HP Seat bad; piston edge damaged Excessive IP Bad HP seat; HP Seat or Piston O-ring (s) bad Leaks between seams on body Bad O-rings;...