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Dive Gear Express DGX Gears D6 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 © 2022 Dive Gear Express All Rights Reserved Revision 3 Published 09/23/2022 Revision Date Changes 02/19/2021 Initial publication 10/20/2021 Updated schematic diagram 09/23/2022 Minor technical edits for clarity; replaced Fig. 3; removed Figs. 4 and 5 and renumbered subsequent Figs.; replaced Figs.
  • 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. (12) Only use degreasers that leave no organic residue (e.g., Extreme Simple Green, Blue Gold Cleaner, or any clear liquid dish soap that does not contain scents or dyes). (13) To remove corrosion, use a 50/50 vinegar/water solution and nylon brushes.
  • Page 5 Cleaning of Regulator Parts (16) Cleaning of parts that are going to be reused is one of the most critical steps in servicing the regulator. As was stated earlier, use the proper solutions for the job at hand. Removal of hydrocarbons and debris should be accomplished before attempting removal of corrosion.

  • Page 6: Inspection After Cleaning

    Inspection After Cleaning (21) Before assembling the regulator, it is necessary to inspect all the cleaned components. Using a magnifying glass or inexpensive USB microscope, ensure all parts are clean and contaminant-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 7 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 8 Fig. 3 (1) The First Stage Body Holding Tool, Thin Jaw Adjustable Wrench, Spanner Wrench and Brass O-Ring Pick Set can be found at Dive Gear Express using the link below. https://www.divegearexpress.com/tools/scuba-tools (2) Tools may also be purchased from Scuba Tools at the link below.

  • Page 9: Preliminary Testing

    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 effort and second stage negative pressure test Visual inspection is done to identify issues that could affect servicing and to ensure that pressurizing...
  • Page 10 (4) The standard operating range for the system is with an IP of 135 psi. Ideally, the system is operating at 135 psi +/- 5 psi and show no signs of “creep” or instability at 3000 psi. Caution Note: “Creep” will show as steadily increasing IP while the regulator is not in use.
  • Page 11 4. First Stage Disassembly (1) Additional tips for performing disassembly of the D6 First Stage can be found in our video at: https://www.youtube.com/watch?v=cKMoqbUnomA (2) 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.
  • Page 12 2. Remove the Env Cap (22), Silicone Disk (21), and Transmitter (20) - Fig. 5. It is often easier to remove the cap with the first stage installed on an unpressurized cylinder. It may be necessary to use both pin spanners to loosen the cap if corrosion is present.
  • Page 13 4. Lift the DIN Wheel (07) off the DIN Housing (08) - Fig. 9. Loosen and remove the DIN Housing using a 19mm deep socket or open-end wrench - Fig. 10. Remove the Saddle (10). Fig. 11 shows all parts disassembled at this point.
  • Page 14 6. Turn the regulator over so that the Turret (24) faces up - Fig. 15. Unscrew the Diaphragm Cap assembly - Fig. 16. Fig. 15 Fig. 16 The Diaphragm Cap assembly consists of the Cap (18), the Spring Seat (15), Spring Washers (16*), Main Spring (17), and Adjust Screw (19) - Fig.
  • Page 15 8. Remove the Lifter (12) from the Main Housing by inverting the regulator body to let it fall out - Fig. 20. If the Lifter does not fall free, carefully lift it free to avoid bending the center pin or wait until Step 11.
  • Page 16 10. With the 6mm hex and ratchet, loosen the Turret Bolt (30) - Fig. 22. Do not remove it at this time. Take the first stage handle and regulator out of the vise. Turn the Main Housing vertical as seen, and using the 6mm hex, remove the Turret Bolt - Fig.
  • Page 17 12. Removal of O-ring (27*) requires great care. The sealing of this O-ring with the stem of the HP seat and Turret bolt inner surface is critical to the regulator's safe operation. Using a nylon pick, remove the O-ring by carefully working it out of its location, and then retrieve it with the plastic crochet hook. It is better to work it from the "outside in"...
  • Page 18 14. Carefully inspect the machined orifice in the Main Housing. It should show no evidence of nicks or uneven surfaces on the bevels - Fig. 30. Caution Note: Do not insert any metal tool into the bore of the Main Housing! A scratch on the orifice will cause irreparable IP creep.
  • Page 19 (4) The photographs below show the disassembled first stage - Fig. 31 and the items in the Service Parts Kit - Fig. 32. 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) Additional tips for performing reassembly and tuning of the D6 First Stage can be found in our videos at: https://www.youtube.com/watch?v=Nd5OtVJ8MEc https://www.youtube.com/watch?v=xkvb-rXKcGY (2) Before starting the first stage assembly, complete a thorough inspection of all parts to be reused. Refer to the Overview Inspection section for details.
  • Page 21 2. Install the Diaphragm Washer (14*) in the same manner by inserting one side and pulling it under the lip as you work it into place - Fig. 35. Using the brass spade or nylon pick, smooth the Washer to ensure it is firmly seated below the threads of the Main Housing - Fig.
  • Page 22 4. Turn the Adjust Screw (19) into the Diaphram Cap (18) until 3 to 4 threads are showing as illustrated - Fig. 38. Stack the Washer (16*), Main Spring (17) Washer (16*), and Spring Seat (15) in the Adjust Screw (18). Turn the regulator Main Housing upside down and screw the Cap assembly into it. Hand tighten - Fig.
  • Page 23 6. Turn the Main Housing so that the HP side faces up. Lubricate the O-ring (23*) and place it on the Housing - Fig. 42. Push the Turret (24) onto the Housing and turn it to be sure it is seated and rotates smoothly - Fig.
  • Page 24 8. Place the Valve Spring (26) on the Turret Bolt (30) - Fig. 46. Lubricate the HP Seat (25*) tip by placing it in the bag used to lubricate the O-rings and rotate it. Push the HP Seat stem into the O-ring (27*) until it seats on the Valve Spring (26) as shown - Fig.
  • Page 25 10. If not already done, install the first stage handle in one of the HP ports. Clamp the handle in a vise with the Turret Bolt facing up - Fig. 49. Using the torque wrench and hex socket, torque the Turret Bolt to 170 in-lbs/200 kgf-cm/19 N⋅m - Fig.
  • Page 26 12. Set the DIN Wheel (07) on the DIN Housing - Fig. 53. Place the O-ring (06*) on the Filter (05*) as shown - Fig. 54. Place the pair in the DIN Housing and push into place with the dowel rod - Fig. 55. Fig.
  • Page 27 14. Install the O-ring (02*) into the DIN Retainer (03) - Fig. 58. This completes the assembly of the first stage. Testing and adjustments may now be made. The Transmitter (20), Silicone Disc (21), and Env Cap (22) are not installed until the testing and adjustment steps are complete - Fig. 59. Only install the Transmitter (20), Silicone Disc (21), and ENV CAP (22) when the regulator is pressurized.
  • Page 28 First Stage Torque Specifications (3) 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 N⋅m DIN Housing (08) to Main Housing (11)
  • Page 29 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 30 Housing and Turret, DIN connection, port plugs, and hose connections. If none are present, the first stage service and testing are complete. Caution Note: Do not submerge the second stage with the in-line tool attached or with the plug-in IP gauge on the low pressure inflator. They are made for surface use only and submerging them may result in damage to the tool or gauge!
  • Page 31 (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;...