Dive Gear Express DGX Gears XTRA Regulator Service Manual Download | Manualshive

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DGX Gears XTRA Regulator

Service Manual

DGX Xtra First Stage

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Summary of Contents for DGX Gears XTRA Regulator

Page 1: ...DGX Gears XTRA Regulator Service Manual DGX Xtra First Stage...

Page 2: ...Copyright 2020 Dive Gear Express Author Photographer UDM Consulting All rights reserved Revision 5d Published 8 17 2020...

Page 3: ...ications 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 detailed...

Page 4: ...rrosion use hot soapy water and a soft brush to remove the lubricant Then use the acidic solution to deal with the corrosion 18 Once the corrosion has been dealt with wash the parts using a fresh soap...

Page 5: ...om their individual bags before they are to be used runs the risk of mixing them up Some o rings are very close in size but are not interchangeable Keep the parts in the bags until you actually need t...

Page 6: ...ed In dynamic applications it is used to reduce excessive wear Static o rings do not generally require the use of lubricant 28 Where parts are not necessary to be lubricated it is good practice to avo...

Page 7: ...enches 10 Brass Picks for removing o rings 11 Intermediate Pressure Gauge 12 Tribolube 71 13 Soft Bristle Cleaning Brushes Nylon Recommended tools 1 In line second stage adjustment tool with slotted o...

Page 8: ...Fig 3 Fig 4 Required Tools Recommended Tools Fig 5 Fig 6 Colander Strainers...

Page 9: ...The technician will check all hose connection crimps Defects must be taken care of before pressurizing the system Replacement of any suspect hoses is recommended Caution Note Defects in hoses require...

Page 10: ...on or sealing o rings 5 If the system shows no sign of creep or IP instability it is generally not necessary to rebuild the 1st stage with some exceptions Caution Note If the unit shows signs of inter...

Page 11: ...wing the instructions Be sure to keep all old parts organized and separate from new ones in the service kit 1 Remove all hoses and port plugs Fig 7 Fig 7 2 Remove the DIN Shutter valve D2 using a 4mm...

Page 12: ...one of the high pressure ports and clamp the handle into a vise Fig 10 NEVER CLAMP THE 1st STAGE BODY INTO THE JAWS OF A VISE Fig 10 Caution Note Clamping the body of the regulator into the jaws of a...

Page 13: ...g Filter Retainer and DIN Shutter Crown Fig 12 Use the pinch method and a brass or nylon pick Do not use a steel pick that could damage the sealing surface Set aside the Spring D6 and filter D11 with...

Page 14: ...ig 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 Fig 15 push out the HP seat with a blunt pick remove O ring 32 O ring 30 and...

Page 15: ...visible Fig 18 Fig 17 Fig 18 11 Holding the regulator vertical with the end cap turret on the bottom unscrew the assembly from the main body Fig 19 This allows access to the Piston 14 Washer 12 Spring...

Page 16: ...rass or nylon pick Fig 23 Fig 22 Fig 23 14 Disassemble the turret by inserting a 1st stage handle into one of the low pressure ports Using a 6 mm hex wrench unscrew the Nut 16 from the Port Swivel 23...

Page 17: ...w the disassembled first stage Fig 26 and 1st stage service kit Fig 27 All of the parts not in the service kit need to be washed rinsed and dried as discussed previously Fig 26 Disassembled 1st Stage...

Page 18: ...ch part 1 The first step in assembling the now cleaned 1st stage is to assemble the turret Lubricate the O ring 20 and install it on the port swivel 23 Fig 28 along with Washer 17 Fig 29 Fig 28 Fig 29...

Page 19: ...g 32 Fig 33 4 Next lubricate O ring 15 Fig 34 and install it on the Piston 14 Place the Washer 12 1 on the Piston followed by the Spring 13 Fig 35 and the Washer 12 Fig 36 Fig 34 Fig 35 Fig 36 5 Caref...

Page 20: ...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 There is no torque specification for this Fig 41 Fig 42 8 Set...

Page 21: ...er is torqued to its proper specification install the rubber End Cap 34 onto the regulator body Orient the groove in the side to line up with the DIN Inlet on the body Fig 46 Fig 46 11 Place the Saddl...

Page 22: ...D8 into the Handwheel and torque this to 86 in lbs 100 kgf cm 10 Nm using a 4mm hex Take the DIN Shutter Crown D4 and install one Washer D5 the Spring D6 and the Washer D5 inside of the Shutter Crown...

Page 23: ...ations 1 For a successful rebuild it is necessary to use proper torque on all connections that require it The following specifications should be used First Stage Torque Values Filter Retainer D10 to B...

Page 24: ...ould 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...

Page 25: ...ging them may result in damage to the tool or gauge 7 General Trouble Shooting Not all possibilities may be noted No airflow Check supply pressure Free Flowing Excessive IP High pressure seat bad pist...

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