Dive Gear Express DGX Gears XTRA Service Manual Download Page 2

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Revision 6 Published 9/28/2020

Revision Date

Changes

5d 8/17/2020

Initial publication

6 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; corrected pressure (300 should be

3000) in First Stage Testing; updated schematic diagram

Summary of Contents for DGX Gears XTRA

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

Page 2: ...8 17 2020 Initial publication 6 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...

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: ...ses less lubricant 27 Under most circumstances a lubricant should be used very sparingly or not at all In nearly all scuba applications if you can see the lubricant too much has been applied Before us...

Page 7: ...300 inch pounds range 2 Piston Stem Bushing Assembly Tool Scuba Tools part number 20 150 200 3 Scuba Multi Tool Scuba Tools part number 20 100 200 4 First Stage Body Holding Tool for HP and LP ports 5...

Page 8: ...t Fig 4 2 Where a Scuba Tools part number is noted they can be found at the link below They also have some of the other tools noted but are not the only supplier of them www scubatools com 3 The First...

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: ...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 11: ...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 12: ...service kits are identified in the same way Have the schematic 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 T...

Page 13: ...o one of the high pressure ports and clamp the tool into a vise Fig 10 NEVER CLAMP THE FIRST STAGE BODY INTO THE JAWS OF A VISE Fig 10 Caution Note Clamping the body of the regulator into the jaws of...

Page 14: ...lter Retainer Use the pinch method and a brass or nylon pick Do not use a steel pick that could damage the sealing surface Remove the Filter D11 and set aside along with the Spring D6 and items listed...

Page 15: ...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...

Page 16: ...h 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 Fig 17...

Page 17: ...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 20 12 Remove O ring 15 from the piston using the pinc...

Page 18: ...g 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 22 Fig 23 14 Disassemble the turret by inserting a first stage ha...

Page 19: ...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 r...

Page 20: ...tage 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...

Page 21: ...rings and ensure no debris is trapped on them 1 The first step in assembling the now cleaned first stage is to assemble the turret Lubricate the O ring 20 and install it on the Port Swivel 23 Fig 28 a...

Page 22: ...se 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 Fig 33 Fig 32 Fig 33 4 Next lubricate the O ring 1...

Page 23: ...nsert 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 38 Fig 37 Fig 38 6 Reverse the tool to hold the...

Page 24: ...s secure There is no torque specification for this Fig 41 Fig 42 8 Set the assembly aside and install the O ring 30 in the HP side of the body as shown using a blunt brass or plastic pick and place th...

Page 25: ...his 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 Orient the groove in the side...

Page 26: ...nto 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 Lubricate the three...

Page 27: ...D4 and install first one Washer D5 the Spring D6 and the second Washer D5 inside the Shutter Crown Fig 49 Fig 49 14 Slide the Shutter Crown assembly onto the Retainer Housing Fig 50 It is best to do t...

Page 28: ...l the O ring D3 Then using a 4mm hex torque the Valve to 27 in lbs 31 kgf cm 3 Nm Fig 53 Replace the O rings 22 25 on port plugs 21 24 and replace port plugs and hoses based on the configuration used...

Page 29: ...der 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 Filter Retainer D10 to Body 11 260 in lbs 30...

Page 30: ...ff 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 indica...

Page 31: ...ted 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 excessive...

Page 32: ......

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