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Dive Gear Express XTRA Second Stage, Service Manual

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Dive Gear Express XTRA Second Stage Service Manual Download Page 17

6. Second Stage Assembly 

(1) Before starting the assembly of the second stage, complete a thorough inspection of all parts to be re­
used. Refer 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. 

(2) Using the method described in the Overview, prepare to lubricate the dynamic o­rings. Remember to not 
use excessive amounts of lubrication. 

1. Locate the ­o­rings for the following assemblies: O­rings (31 and 33) for the Adjusting Spring (34). Lubricate 
them and install them on the Adjusting Spring. Place O­ring (16) on the Orifice (15). Install O­rings (26) on the 
Shuttle Valve (25). Install O­ring (29) on the Adjusting Screw (30). At this time, the LP Seat (24) can be placed 
into the end of the Shuttle Valve (25). ­ Fig. 18. 

 

Fig. 18 

2. Install O­ring (22) on the Valve Spindle (19) after lubricating it. Install O­ring (23) in the interior groove of 
Valve Spindle on the side shown in Fig. 19.  

 

Fig. 19 

 

 

Summary of Contents for XTRA Second Stage

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

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

Page 3: ...fications 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 notes in an accessible location for their own observations and service tips as well as a record of service 7 Throughout the text parts are referenced using the item number on the schematic to facilit...

Page 4: ...orrosion 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 and water solution while wearing nitrile gloves to reduce the risk of contaminating the parts with skin oils Rinse the parts with clean running water distilled is preferred that is allowed to drain ...

Page 5: ... segregated Remove the new parts from the service kit bag and lay them out in the order they will be used Do not take the new parts out of the bags yet Caution Note Removing parts from 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 them 24 As with the...

Page 6: ...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 avoid getting any lubricant on them Primarily when the regulator is used with high O2 content mixes It also helps to keep those parts clean and free of debris that will cling to the lubricant 29 Maintaining oxygen clean conditions...

Page 7: ...rass Picks for removing o rings 4 Tribolube 71 5 Soft Bristle Cleaning Brushes Nylon 6 In line second stage adjustment tool with slotted orifice selected 7 Wooden or plastic dowels Recommended tools Fig 4 1 Soft Rubber Pad 2 Magnifying Glass 3 Flashlight 4 UV light 5 Magnahelic Gauge with 0 3 inches of water scale Fig 5 6 Waterproof Ruler Scale for testing when no magnahelic is available 2 You can...

Page 8: ...Fig 3 Fig 4 Required Tools Recommended Tools Fig 5 Magnehelic ...

Page 9: ...e 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 replacement before pressurizing the regulator Failure to do so may result in serious injury or death 5 Detailed Visual Inspection of the SPG and connection The technician will check the SPG for any ...

Page 10: ...s Caution Note If the unit shows signs of internal corrosion or the filter shows evidence of contamination the unit must be rebuilt Regardless of the Intermediate Pressure 9 The regulator will require rebuilding if small bubbles are leaking from between the turret retainer and main body from under the rubber cap or out of the high pressure seat retainer Knowledge of flooding of the first stage wil...

Page 11: ...en 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 used This permits a break in period for the LP seat It is normal to see this initial setting drop as the LP seat takes a set Second Stage Case Integrity 3 The case should be inspected for signs of damage Scratches gouges missin...

Page 12: ...izing the system Unscrew the Case Cover 4 1 from the Case 11 and remove the Cover 3 Diaphragm Cover 4 and the Diaphragm 06 and Diaphragm Disc 05 assembly Fig 6 This reveals the Valve Spindle Assembly in the case Fig 7 Fig 6 Fig 7 2 Remove the Retaining Nut 08 Holding the Lever 20 down slide pull the Valve Spindle Assembly out of the case as one unit Fig 8 Fig 8 3 Slide the Venturi Lever 18 off of ...

Page 13: ...usting Spring 34 from the Adjusting Screw Fig 10 Fig 10 5 Holding the lever upright use the 1 8th inch plastic or wooden dowel to push the assembly consisting of the LP seat 24 Shuttle Valve 25 O rings 26 Spring 27 and Counter Balance Cylinder 28 out of the Spindle You may hear a slight click as you do this when the LP seat end passes the lever Fig 11 An alternative method is to carefully remove t...

Page 14: ...e 19 The photo below shows all of the parts to the Spindle Assembly Item O ring 23 is located in a groove on the inside of the Spindle Fig 12 Fig 12 7 Using a brass pick carefully remove O ring 23 from the Spindle Fig 13 Confirm that O ring 09 from the air inlet side of the Case has been removed from the groove that contains it Fig 14 Fig 13 Fig 14 ...

Page 15: ... press the small tab slightly on the adjustment lever side of the case in the exhaust port to remove the Cover Exhaust Valve 13 Fig 16 Be careful not to snap the tab off Gently remove the cover as you press the tab Do not try to pry it off without pressing the tab The Exhaust Valve 12 can be removed by pulling it out of the hole intact or by cutting the stem inside the case and pulling it out Repl...

Page 16: ...Second Stage disassembled Second Stage Service Kit ...

Page 17: ...ember to not use excessive amounts of lubrication 1 Locate the o rings for the following assemblies O rings 31 and 33 for the Adjusting Spring 34 Lubricate them and install them on the Adjusting Spring Place O ring 16 on the Orifice 15 Install O rings 26 on the Shuttle Valve 25 Install O ring 29 on the Adjusting Screw 30 At this time the LP Seat 24 can be placed into the end of the Shuttle Valve 2...

Page 18: ...ented as shown in Fig 22 insert it into the Spindle 19 Pay special attention to the position of the notch on the Shuttle Valve This is where the Lever 20 engages the Shuttle Valve It must be oriented in this manner Note also the position of the hole for the Spring Pin 21 Fig 22 Lever removed for clarity Fig 22 5 Carefully insert the assembly the rest of the way into the spindle It is critical to m...

Page 19: ...r Fig 24 Fig 24 7 Allow the lever to come down to rest and carefully set the assembly aside Fig 25 Fig 25 8 Assemble the Adjusting Screw 30 and Adjusting Spring 34 Fig 26 A trace of lubricant on the threads of these will help to ensure smooth operation The initial adjustment on the Adjustment Spring is to have approximately 1mm of the spring end showing above the end of the Adjusting Screw 34 as s...

Page 20: ...it into place with the blunt end of the brass pick Fig 29 The sharp brass pick may be used to guide it in An equal amount of pin should be present on each side If this is not done the Venturi Lever may hang up on the pin that is sticking too far out Fig 29 11 Place the lubricated O ring 17 on the Venturi Lever 18 and slide it onto the Spindle Lever assembly Make sure that it moves freely around th...

Page 21: ...k the case Fig 31 Fig 32 13 Turn the Case so that the Adjusting Spring 34 can be seen Fig 31 Install the Rubber Cap 35 onto the Adjusting Screw 30 to cover the spring Fig 32 Fig 33 Fig 34 14 Using the In Line Adjusting Tool while depressing the Lever 20 turn the orifice so that the Lever 20 is even with the face of the Case 11 Only turn the orifice when the lever is depressed to avoid cutting the ...

Page 22: ...it in the Case 11 Place the Diaphragm Cover 04 in position Fig 37 Fig 36 Fig 37 16 Place the Cover 03 and secure it with the Case Cover 4 1 Fig 38 If the Exhaust Valve 12 has been replaced and the Cover Exhaust Valve 13 has been removed it can now be replaced Fig 39 Re install the Mouthpiece 14 and secure it with a zip tie Fig 38 Fig 39 This completes the assembly of the second stage ...

Page 23: ... to start Re test 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 several normal breaths from it If the breaths require significant effort depressurize the system and with the purge button depressed turn the orifice counter clockwise one half turn and re test As with the clockwis...

Page 24: ... 3 Cracking pressure should initially be set at 1 to 1 2 inches of water This will account for the decrease that will be seen as the regulator is used As the seat begins to form the groove between it and the orifice knife edge cracking pressure will decrease If necessary it can be increased by removing the rubber plug on the Adjustment screw and increasing spring tension by turning the Adjustment ...

Page 25: ......

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