Dive Gear Express DGX Gears D6 Second Stage Service Manual Download Page 1 | Manualshive

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DGX Gears D6

Second Stage Service Manual

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Summary of Contents for DGX Gears D6

Page 1: ...DGX Gears D6 Second Stage Service Manual...

Page 2: ...n 2 Published 09 23 2022 Revision Date Changes 1 02 19 2021 Initial publication 1a 03 25 2022 Replaced photo for Fig 28 2 09 23 2022 Minor technical edits for clarity replaced Fig 3 removed Figs 4 and...

Page 3: ...tains the detailed parts lists The diagram also includes the torque specifications for parts where required 6 A general troubleshooting guide with space for notes is also included for those using a pr...

Page 4: ...on use a 50 50 vinegar water solution and nylon brushes Areas of heavy corrosion not removed with vinegar can be addressed with mild phosphoric acid solutions available from scuba supply houses 14 All...

Page 5: ...ionally and allow parts to stand in the acidic solution for ten minutes Wearing gloves remove and inspect parts and reimmerse them for an additional ten minutes if visible corrosion is still noted Rem...

Page 6: ...to be replaced have been discarded or segregated Caution Note Removing parts from their packaging before they are to be used runs the risk of mixing them up Some O rings are very close in size but ar...

Page 7: ...aringly or not at all In nearly all scuba applications if you can see the lubricant too much has been applied Before using any lubricant any existing lubrication should be removed before new is applie...

Page 8: ...Tool Hex Adjusting Tip Fig 3 1 The In Line Adjusting Tool with 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 tool...

Page 9: ...ns to make sure they are secure Check that on the first stage there are no extruded O rings and hoses are tight Detailed inspection of hoses is done to ensure it is safe to pressurize the regulator se...

Page 10: ...the second stage will open The normal range for the adjustable second stage is 1 0 to 2 2 inches of water Less pressure may be desired by the diver but the initial factory setting of 1 1 should be us...

Page 11: ...same way Have both in front of you while following the instructions Be sure to keep all old parts organized and separate from new ones in the service kit The old washers and O rings marked with an as...

Page 12: ...and gently press all around the edge to check that it is pliable and not stuck or torn Fig 8 Fig 6 Fig 7 Fig 8 3 Slide the Deflector Knob 16 off the assembly while holding down the Lever Fig 9 After...

Page 13: ...low the Adjust Knob to be removed Remove the O ring 20 from the Adjust Tube 17 Fig 12 Fig 11 Fig 12 5 Remove the Knob Adjust Core 29 from the Adjust Knob with a pick Insert the pick and pop the core o...

Page 14: ...at end passes the Lever Remove the Lever from the Adjust Tube Fig 15 An alternative method is to carefully remove the Lever by lifting one leg out of the hole and rotating the Adjust Tube to allow the...

Page 15: ...h a thin wooden dowel from the threaded end Do not use a metal tool Remove the O ring 14 from the Orifice Fig 18 Fig 18 9 The disassembled Adjust Tube assembly with the Heat Sink Nut is shown below No...

Page 16: ...er is fitted in such a way at the factory that removing it is likely to damage the Cover Removal may also damage the flange that holds it in place Fig 21 Fig 20 Fig 21 If removal to replace the Exhaus...

Page 17: ...nd stage Fig 22 and the Service Parts Kit Fig 23 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...

Page 18: ...efer to the Overview Inspection section for details At this time open the service kit and lay out the parts Use the schematic to identify each part Caution Note Only use enough lubricant to lightly co...

Page 19: ...le the Balance Cylinder 25 Main Spring 24 and Piston as shown in Fig 26 Fig 26 3 Place the O ring 14 on the Orifice 13 Fig 27 Insert the Orifice into the Adjust Tube 17 using the 3 16 hex Fig 28 Fig 2...

Page 20: ...4 Turn the Orifice clockwise into the Adjust Tube 4 5 turns until the threads have engaged Fig 29 Fig 29 5 Lubricate the O ring 20 and place it in the groove on the Adjust Tube 17 Fig 30 Fig 30...

Page 21: ...the step s orientation on the Piston and the air outlet of the Adjust Tube Fig 31 Fig 32 shows how it should appear as the step passes the air outlet opening Fig 31 Fig 32 7 Slide the Piston assembly...

Page 22: ...y as this may cause the Piston to move and the Lever not to engage the step Fig 34 Fig 34 9 Install the unlubricated O rings 28 and 30 on the Knob Adjust Core 29 and insert the Core in the Adjust Knob...

Page 23: ...g 36 Fig 37 11 Screw the Adjust Knob assembly into the tube until you can see clearly through the hole for the Pin 19 As the assembly is turned in the Lever will rise Fig 38 If it does not it may have...

Page 24: ...t Knob is screwed in far enough to see clearly through the opening Fig 39 Position the Pin evenly so that equal amounts are visible on each side Fig 40 Fig 39 Fig 40 13 Lubricate the O ring 15 and pla...

Page 25: ...the Deflector Knob and the Adjust Knob to ensure they move smoothly Fig 42 Fig 43 15 Slide the Adjust Tube assembly into the Main Housing 01 Fig 44 Make sure the assembly is all the way in and the fla...

Page 26: ...16 Install the O ring 04 and the Heat Sink Nut 05 on the Adjust Tube Fig 46 Fig 46 17 Carefully tighten the Heat Sink Nut to secure the Adjust Tube Fig 47 Do not overtighten Fig 47...

Page 27: ...e of the Housing Fig 48 Only turn the Orifice when the Lever is depressed to avoid cutting the LP Seat This is the preliminary adjustment of the cracking pressure The final adjustment will be made wit...

Page 28: ...ver assembly 08 09 and 10 Fig 51 Reinstall the Mouthpiece 03 and secure it with the Tie Wrap 02 Adjust as needed and use the snips to trim the end of Tie Wrap Fig 51 This completes the assembly of the...

Page 29: ...sixth turn to start Retest Depending on where the Orifice was initially set it may be necessary to do this several times 3 If the second stage does not flow on the initial pressurization attempt sever...

Page 30: ...e the air begins to flow using a ruler attached or held to the stage This method is not always as accurate as using a magnehelic but still yields acceptable results Caution Note Do not leave the In Li...

Page 31: ...Lever not seated and has dropped Free Flowing Orifice adjusted too loosely LP Seat bad excessive IP Hard to inhale Lever bent or restricted adjusted with a too high cracking pressure Wet breathing Cr...

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