Dive Gear Express DGX Gears XTRA, Service Manual

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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. 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 135 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 begin 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 and turret, 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!