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Dive Gear Express DGX Gears XTRA Service Manual
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Dive Gear Express DGX Gears XTRA Service Manual

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DGX Gears XTRA
First Stage Service Manual

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Summary of Contents for Dive Gear Express DGX Gears XTRA

  • Page 1 DGX Gears XTRA First Stage Service Manual...
  • Page 2 Copyright © 2020 Dive Gear Express All Rights Reserved Revision 6 Published 9/28/2020 Revision Date Changes 8/17/2020 Initial publication 9/28/2020 Edited photos for clarity and added part numbers; replaced photos for Figs. 26, 30, 32, 33; edited text: disassembly items 6. and 15., assembly items 1., 2., 8. and 15.; added torque for port plugs;...
  • 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 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 tools make servicing easier or more efficient, as well as 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 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. Remove the Retainer Housing (D8) with the 4mm hex and lift the Handwheel (D9) from the body – Fig. 9. Fig. 9 4. Insert the First Stage Body Holding Tool into one of the high pressure ports and clamp the tool into a vise –...
  • Page 14 5. Using a ¾ inch socket and ratchet loosen the Filter Retainer (D10) – Fig. 11. Be sure to hold the socket firmly so that it does not slip. Using steady, even pressure remove the Retainer and Saddle (08). Fig. 11 6.
  • Page 15 7. Using the Multi-Tool, carefully remove the rubber End Cap (34) – Fig. 13. This exposes the HP Seat Retainer (33) – Fig. 14. Fig. 13 Fig. 14 8. Loosen the HP Seat Retainer with a 5mm hex wrench and remove it from the body, exposing the HP Seat (31*) –...
  • Page 16 9. Push out the HP Seat with a blunt pick, remove O-ring (32*) and Spring (29). Remove O-ring (30*) with a brass or nylon pick from its groove in the body of the regulator – Fig. 16. Fig. 16 10. Using the universal wrench or a pin spanner with an appropriate pin, and with the first stage handle secure –...
  • Page 17 11. Holding the regulator vertical, with the end cap/turret on the bottom, unscrew the assembly from the Body (11) – Fig. 19. This allows access to the Washer (12*), Spring (13), Washer (12-1*), and Piston (14) – Fig. 20. Fig. 19 Fig.
  • Page 18 13. Carefully remove the following components from the HP side of the regulator Body: Washer (28), O-ring (27*), and Teflon Washer (26*) using the Piston Stem Bushing Assembly Tool – Fig.22. Turn the Body over and remove the other O-ring (27*) with a brass or nylon pick – Fig. 23. Fig.
  • Page 19 15. This allows access to the Washer (17a). Remove the Washer. Pull the End Cap from the Port Swivel and remove the Washer (17b) and O-ring (20*) from the Port Swivel – Fig. 25. Take note of the Washers. The smaller one (a) goes into the End Cap and the larger (b) onto the Port Swivel at reassembly. Fig.
  • Page 20 (3) The photographs below show the disassembled first stage – Fig. 26 and First Stage Service Parts Kit – Fig. 27. 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 21 5. 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 22 3. Set this assembly aside and install one of the O-rings (27*) into the groove on the regulator body that the End Cap/Port Swivel assembly screws onto – Fig. 32. Use the Piston Stem Bushing Assembly Tool and on the narrower end place in the following order the Washer (28), lubricated O-ring (27*), and Teflon Washer (26*) –...
  • Page 23 5. Carefully slide the Piston Assembly into the End Cap/Port Swivel Assembly – Fig. 37. Using the previously assembled Washer/O-ring/Teflon Washer stack, insert the stack into the HP side of the regulator Body (11), as shown on the schematic. Slightly twist the tool, and the stack will come off in the body - Fig.
  • Page 24 7. Install the first stage handle into a high pressure port - Fig. 41. Use the Multi-Tool to tighten the End Cap/Port Swivel assembly to the Body. A piece of rubber may be used to lessen the chance of scratching the End Cap - Fig. 42. Tighten the connection so that no gap is visible, and the connection is secure.
  • Page 25 9. Install the HP Seat Retainer into the Body and torque this to 130 in lbs/150 kgf cm/15 Nm - Fig. 45. Fig. 45 10. Once the HP Seat Retainer is torqued to its proper specification, install the rubber End Cap (34) onto the regulator body.
  • Page 26 11. Place the Saddle (08) over the DIN Inlet. Insert the Filter (D11) and O-ring (D7*) into the Filter Retainer (D10), as shown on the schematic diagram - Fig. 47. Fig. 47 12. Torque the Filter Retainer to 260 in lbs/300 kgf cm/30 Nm. Set the Handwheel (D9) on the Filter Retainer.
  • Page 27 13. Insert the Retainer Housing into the Handwheel and torque this to 86 in lbs/100 kgf cm/9.7 Nm using a 4mm hex. Take the Shutter Crown (D4) and install first one Washer (D5*) the Spring (D6) and the second Washer (D5*) inside the Shutter Crown - Fig. 49. Fig.
  • Page 28 15. Lubricate the O-ring (D1*) and install it on the Shutter Valve (D2) - Fig. 51. Slide the Shutter Valve into the Crown - Fig. 52 and install the O-ring (D3*). Then using a 4mm hex, torque the Valve to 27 in lbs/31 kgf cm/3 Nm - Fig.
  • 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: Nut (16) to Port Swivel (23) to End Cap (19) 70 in lbs/81 kgf cm/7.9 Nm HP Seat Retainer (33) to Body (11) 130 in lbs/150 kgf cm/15 Nm...
  • Page 30 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;...