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Dive Gear Express DGX Gears FIRST, First Stage Service Manual, Page: 30 / 32

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Dive Gear Express DGX Gears FIRST First Stage Service Manual Download Page 30

6. First Stage Testing 

 

(1) To test the first stage, a regulated breathing air supply, OCA Grade Source, if the regulator is to be 

used with Nitrox, or several SCUBA cylinders are needed. 

It is also necessary to use a second stage 

for testing the regulator even it is only used as an inflator regulator. 

If using a regulated supply, set 

the initial supply to 500 PSI. If using cylinders, 3 are recommended with 500 PSI, 1500 PSI, and 3000 

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. 

https://www.divegearexpress.com/dgx-transfill-hose-with-analog-gauge

 

(2) Attach a second stage with a hose with an in-line tool/IP gauge combination, or a second stage with 

a hose and a low pressure inflator hose with plug-in IP gauge. With the supply set to 500 PSI, slowly 

pressurize the regulator while slightly purging the second stage to act as a safety. 
(3) Allow the second stage to slightly flow and release the purge button slowly. Observe the IP. It should 

come up to 120 PSI +/- 5 PSI and stay at that reading. Breathe the second stage or depress purge 

button 25 to 50 times. Observe the IP. It should drop slightly, 5-10 PSI, on each purge, then come back 

up. If the IP goes above 145 PSI and continues to climb, shut off the air supply and purge the regulator 

to avoid damaging it.  

Caution Note:  If the Intermediate Pressure (IP) goes over the recommended level 

and continues to climb, an issue with the regulator is indicated. It could be an 

issue with the HP seat, the  sealing surface between an O-ring and another 

component, a damaged Piston knife edge, or a missing component. The regulator 

will need to be disassembled, inspected carefully, and rebuilt again. It cannot be 

tested further with an improper IP. 

(4) If the IP is stable, listen for any leaks. If none are noted, the testing can continue. 
(5) Next, increase the supply to 1500 PSI and repeat the procedure. Observe the IP and ensure that it is 

not creeping. It may drop a few PSI as the seat and the piston edge begins to develop a groove. This is 

normal and does not indicate a problem. 
(6) Now increase the supply pressure to 3000 PSI and repeat the procedure as before. The IP should 

be steady and show no signs of creep or drop below the recommended range. 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 body sections, DIN connection, 

port plugs, and hose connections, and if none are present, the first  stage service and testing is 

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! 

 

 

Summary of Contents for 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 4 10 7 2020 Initial publication 4a 3 31 2021 Added text to 5 Regulator First Stage Assembly 1...

Page 3: ...specifications for parts where required 6 A general troubleshooting guide with space for notes is also included for those using a printed version Those who prefer an electronic version should keep det...

Page 4: ...you have a buildup of corrosion you may also have lubricant on the surface of the part Before dealing with the corrosion use hot soapy water and a soft brush to remove the lubricant Then use the acid...

Page 5: ...ly can begin Make sure all old parts that are to be replaced have been discarded or segregated Remove the new parts from the main service kit bag and lay them out in the order they will be used Do not...

Page 6: ...ry to be lubricated it is good practice to avoid getting any lubricant on them especially when the regulator is used with high oxygen content mixes It also helps to keep those parts clean and free of...

Page 7: ...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 use...

Page 8: ...le torque wrench 3 8 drive 0 300 inch pounds range 2 First Stage Body Holding Tool for HP and LP ports 3 3 4 inch or 19mm 3 8th drive deep socket a crowfoot may be substituted 4 1 5 inch or adjustable...

Page 9: ...fying glass 5 Flashlight 6 UV light 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 divegearex...

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: ...eck all hoses looking for evidence of possible failure The technician will check all hose connection crimps Defects must be taken care of before pressurizing the system Replacement of any suspect hose...

Page 12: ...is would indicate a problem with the High Pressure Seat Piston or sealing O rings 5 If the system shows no sign of creep or IP instability it is generally not necessary to rebuild the first stage with...

Page 13: ...vice kits are identified in the same way with some differences which are noted on the schematic Have the schematic in front of you while following the instructions Be sure to keep all old parts organi...

Page 14: ...de up Fig 10 In this orientation you will remove the DIN Retainer B2 and the DIN Knob B4 Fig 10 4 Using the 6mm hex remove the DIN Retainer Fig 11 This exposes the DIN Filter B5 Lift the DIN Knob off...

Page 15: ...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 14 Laying the regulator flat on th...

Page 16: ...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 t...

Page 17: ...pring 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 Pist...

Page 18: ...pring 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 The Bullet and O ring are...

Page 19: ...tage 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...

Page 20: ...includes one low pressure O ring 11 for use on the OPV included with most packages plus one high pressure O ring 13 for use on the SPG included with most packages Additional LP or HP O rings are not...

Page 21: ...t on the edge of the Piston Fig 24 Ensure the O ring is seated in the groove Fig 25 Fig 24 Fig 25 3 Install the HP Seat 17 at the end of the Piston Fig 26 Use the end of a wooden or plastic dowel to e...

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: ...on a flat surface screw the Upper Body 14 onto the assembly Fig 32 Caution Note The amount of spring tension here is significant Having the Lower Body held firmly on a flat surface will aid in overco...

Page 24: ...together by hand until no gap is seen Fig 34 Fig 33 Fig 34 9 Using the pin spanner and first stage handle tighten the body connection There is no torque specification for this Make sure it is snug The...

Page 25: ...g 38 11 Clamp the regulator with the air inlet side up in the vise using the first stage handle Screw the DIN Housing into the Upper Body Fig 39 and torque this to 260 in lbs 300 kgf cm 30 Nm Fig 40 F...

Page 26: ...41 Fig 42 13 Torque the DIN Retainer to 150 in lbs 170 kgf cm 17 Nm using the 6mm hex Fig 43 Fig 43 Caution Note Note that the differences in torque for the DIN Housing and DIN Retainer are necessary...

Page 27: ...ure Valve OPV Fig 44 Fig 44 15 This step is optional Ideally when the regulator is serviced the OPV should be replaced If the OPV is not being replaced and servicing is required use the Bullet O10 fro...

Page 28: ...esult 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 se...

Page 29: ...que 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 Retain...

Page 30: ...If the IP goes above 145 PSI and continues to climb shut off the air supply and purge the regulator to avoid damaging it Caution Note If the Intermediate Pressure IP goes over the recommended level an...

Page 31: ...ck 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 excessive IP body end caps...

Page 32: ......

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