Dive Gear Express DGX Xtra First Stage User manual

DGX Gears XTRA Regulator
Service Manual
DGX Xtra First Stage

Copyright © 2020 Dive Gear Express
Author/Photographer – UDM Consulting
All rights reserved.
Revision 5d Published 8/17/2020



1.Overview
(1) The availability of subassemblies and components, repair parts, specialized tools, and maintenance
manualsdoesnotimplyqualificationtoassembleand/orservicescubaequipment.Improperserviceofdive
equipmentcanleadtosevereinjuryordeath.DiveGearExpressrecommendsthatnonqualifiedindividuals
seekprofessionaltraining/mentoringbeforeattemptingrepairsorservicingonanydivingequipment
Failuretofollowtheproceduresoutlinedhereinmayresultininjuryordeath!
(2)Inthefollowingpageswillbefound,thedisassembly,assembly,tuning,andtroubleshootingstepsfor
thesecomponents.Photosareusedthroughouttoillustratetheprocedures.
Pleasepayspecialattentiontoallcautionnotes!
(3)Wheneveranitemofextraimportanceneedstobeobserved,a“CautionNote:”willappear,followedby
therequiredinformation.Seebelow.
CautionNote:Thismustbereadandfollowed!
(4) Included in this manual is a list of recommended/required tools for each disassembly, assembly, and
testingsection.Theyareidentifiedineachsectionwheretheyareused.
(5) Schematics are located inthe rear of this manual. The drawings containthe detailed parts lists. The
drawingsalsoincludethetorque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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facilitatelocating
eachindividualcomponent
(8)Photographsofthepartskitsareshowntoillustratethateachcomponentisindividuallybagged.Parts
shouldnotbetakenoutoftheirpackaginguntiltheactualassemblystageisreached,andtheuserisready
tolubricate,wherenecessary,andinstallthem.
(9) Ensure the service area is free of any environmental concerns that may cause problems during the
servicing of your regulators. The area must be clean and organized. The use of nitrile gloves is highly
recommendedforthefinalrinsingandassemblystages.Thiswillminimizetheriskofskinoils,contaminating
theinternalcomponentsoftheregulator.
(10)Ensurethatallrequiredservicing/testingairsuppliesareavailableandatthepropertestpressures,if
not using a regulated supply from a single source. This would include the use of cylinders of compressed
breathing air from an OCA grade source if you wish to maintain the oxygenclean status of the unit.
CautionNote:Onlyuseairfromabreathingairsource!
 



CleaningandRinsingGeneralConsiderations

(11)Cleaningandrinsingofthecomponentsshouldbedoneusingclean,freshwater.Ifavailable,distilled
waterisrecommendedtomaintainoxygencleanliness.
(12) Only use degreasers that leave no organic residue (clear Simple Green, dyefree Dawn dishwashing
liquid,orBlueGoldCleanerasexamples).
(13)Todealwithcorrosion,usea50/50vinegarwatersolutionandnylonbrushes.
(14)Allowpartstoairdrywithouttheuseofclothsthatmayleavefibers.Forregulatorsthataregoingtobe
used with Oxygen percentages above 40%, a UV light is strongly recommended to check for organic
contamination.
(15)Onceallserviceprocedureshavebeencompletedandbenchtestingdone,inwatertestinginaconfined
environment such as a swimming pool is recommended to confirm proper function before taking the
regulatoronanactualdive.

CleaningofRegulatorParts
(16)CleaningCleaningofthepartsthataregoingtobereusedisoneofthemostcriticalstepsinservicing
theregulator.Aswasstatedearlier,usethepropersolutionsforthejobathand.Vinegarandwaterarenot
asusefulforremovinglubricatinggreaseasoneofthedetergentsthatwerenoted.Bythesametoken,
thosedetergentsarenotasefficientasthevinegar/watermixindealingwithcorrosivebuildup.
(17)Therefore,where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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freely.Aplasticpastacolanderavailableatany
storeisexcellentforthis.Forverysmallparts,ameshstrainerforsinkdrainsworkswell.Oftensoldasa
set,theyareinexpensiveandcanbeusedformanytypesofregulatorcomponents.Seethephotographsof
eachinthetoolsection.
(19)Afterwashingandrinsingtheregulatorparts,allowthemtoairdry.Usingadryingrackwillaidinthis,
aswellashavingtheairintheroomcirculating.Donotlaythepartsonapaperorclothtowel.Doingsoruns
theriskofhavingfiberssticktothemthatwillcauseissueswithsealing.Inadditiontothis,fiberscanbea
hazardwhenusingtheregulatorwithhighoxygencontentmixes.
(20)Oncethepartshavedriedcompletely,laythemoutinorderofassemblyonthepadusedonthework
surface.Makingsurethatithasbeencleanedandisfreeofcontaminants.Arubberorsiliconematofsuitable
sizeworkswellforthis.Youcanalsousesmallcleancontainerstokeepthepartsorganized.Oncetheparts
have beencleanedand dried,theyneed to beinspected beforestarting theassemblyprocess.Thisis to
ensure that no damage or defects exist that were hidden by corrosion, residual lubrication, or other
contaminantsthathavenowbeenremoved.



InspectionAfterCleaning
(21)Beforeassemblingtheregulator,itisnecessaryto inspectallofthecleaned components. Usingthe
magnifyingglass,checkthecomponentsfordamagethatmayhavebeenhiddenbycorrosionorlubricant.
Lookforscratchesthatmayaffectthesealingoftheregulator.Inadarkenedroom,usetheUVlighttolook
fororganicmaterial.Ifanyarepresent,recleanthepart!Thisiscriticalforusewithoxygenpercentages
above50%!
(22)Anotherwaytocheckforresiduallubricantsistofillatraywithclean,fresh,waterdeepenoughtocover
thepartsbyaninchorso.Laythecomponentsinandcirculatethewater.Allowthepiecestosoakforseveral
minutes.Onceithassettled,lookforarainbowsheenonthesurfaceofthewater.Anyresiduallubricants
willfloatandforma“slick”onthesurface.Ifoneispresent,thepartsmustbecleanedagain.
(23)Nowthatallpartshavebeencleanedandchecked,theassemblycanbegin.Makesurealloldpartsthat
aretobereplacedhavebeendiscardedor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partsthathavebeencleaned,itisagoodideatoinspectthenewpartsaswell.Especially
theHPseat.Makesureitisfreeofanydefects.Checkalloftheoringsandinspectthemasyouusethemfor
nicksorotherconcerns.Inspectthewasherstoensuretheyarefreeofexcessburrsorotherconcernsthat
couldaffecttheirfunction.Itisalsoagoodideatousethepartslistontheschematictoensurethatallofthe
newpartsthatareneededarepresentandaccountedforintheirrequiredquantities.

(25)LubricationofOrings;Lubricationcanbeoverdone.Doingsorunstheriskoftrappingexcessdirtor
debrisontheparts.Onewayofreducingtheriskofoverdoingitistousethelubeinabagmethod.This
involvesusingasmallcleanplasticbagandputtingasmallamountoflubeinit.Thentheoringisinserted
intothebag,workedaround,excesssqueezedoff,andtakenoutofthebag,andusedinitslocation.


Fig.1Fig.2.
(26)AnotherwayistoapplyasmallamountofTribolubetotheglovedindexfingerandmassagetheoring
betweenthethumbandindexfinger.Eitherwayworks,butthebagmethodtendstogivebetterdistribution
resultsanduseslesslubricant.



(27)Undermostcircumstances,alubricantisusedcorrectlyverysparinglyornotatall.Innearlyallscuba
applications, ifyoucan see thelubricant, you’ve usedtoomuch. Before using any lubricant, any existing
lubricationshouldberemovedbeforenewisapplied.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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.

Thenextsectionliststhetoolsyouwillneedtoservicetheregulator.
 



2.TOOLLIST

(1) The tool list has been divided into two sections. Required and Recommended. Required tools are
necessaryforservicingtheregulator.Recommendedarethoseitemsthatmakeservicingeasierormore
efficientaswellaslesseningthechanceofdamage.
Requiredtools
1. AdjustableTorqueWrench3/8drive0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. 1stStageHandleforHPandLPports
5. 3/4inch3/8thdrivesocket
6. 6mm3/8inchdriveHexHeadmalesocket
7. 5mm3/8drivehexsocket
8. 4mm3/8drivehexsocket
9. 2AdjustableWrenches
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orificeselected
2.Softjawedvise
3.Woodenorplasticdowels1/8–3/16diameter
4.SoftRubberPad
5.MagnifyingGlass
6.Flashlight
7.UVlight

(2)Whereapartnumberisnoted,ScubaToolsisthesourceofthatitem.Theyalsohavesomeoftheother
toolsnotedbutarenottheonlysupplierofthem.
ScubaTools
www.scubatools.com
Phone:3366432599

(3)YoucanalsopurchasetoolsfromDiveGearExpress.The1ststagehandle,InLineAdjustingToolwithIP
gauge,PinSpanner,BrassPicks,andtheIPGaugethatisshownthatplugsintotheLPinflatorhosecanbe
foundatthelinkbelow.
https://www.divegearexpress.com/tools/scubatools
Phone:9549776009



 
Fig.3Fig.4
RequiredToolsRecommendedTools


 
Fig.5Fig.6
ColanderStrainers
 



3.PreliminaryTesting
(1)Preliminarytestingoftheregulatorisnecessarytoidentifyanyissueswiththefirstandsecondstagesand
verifytheoverallregulatorfunction.Thistestingwillinclude:
1. Visualinspectionofthefirstandsecondstages
2. Inspectionofthehoses
3. IntermediatePressurecheck
4. CrackingPressureandSecondStageNegativePressureTest

Visual inspectionisdonetoidentifyissuesthatcouldaffectservicingandtoensurethat pressurizingthe
systemwillnotcompromisethesafetyoftheservicetechnician.
Thetechnicianwillcheckallconnectionstomakesuretheyaresecure.
Thetechnicianwillcheckthatonthefirststage,therearenoextrudedorings,andhosesaretight.
ThetechnicianwillchecktherearenodefectstotheSPG.
ThetechnicianwillensurethattheDINassemblyissecure,andtheOringisintactandabletoformaseal.
Thetechnicianwillinspectthefilterforsignsofdiscoloration.
DetailedInspectionofHosesisdonetoensureitissafetopressurizetheregulatorset.
Thetechnicianwillcheck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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!
(2)DetailedVisualInspectionoftheSPGandconnection–ThetechnicianwillchecktheSPGforanysigns
ofcrackingof theface, waterintrusion,and corrosionaround theSPG to thehose connection.Ifusing a
consoleorboot,itisnecessarytoremovetheSPGfromtherubberboot.Oncethisisdone,theHPspool
shouldbeinspectedand,ifnecessary,replaced.
(3)CheckingofIntermediatePressure(IP)–TheIntermediatePressure(IP)ofthesystemshouldbetested
only after the preceding checks have been done to ensure technician safety. Checking of intermediate
pressureisdonebyattachinganintermediatepressuregaugetotheLPpressureinflatorhose.Thesystemis
thenpressurizedwhilepartiallydepressingthepurgebuttonononeofthesecondstages.Depressingthe
purgebuttonslightlyonthesecondstageisdonetopreventfurtherdamagetothesystembyprovidinga
reliefvalveshouldtheIPriserapidlytounsafelevels.Oncethesystemhasbeenpressurized,thepurgeis
released,andtheIPchecked.
 



CautionNote:
Ifthesecondstageisleakingevenslightly,IPwillbeaffected.Ifthesecondstageis
leaking,turntheadjustmentknobtostopitoruseasecondstagethatisnotleaking
throughwhenpairedwiththefirststage.
(4)ThestandardoperatingrangeforthesystemiswithanIPof135PSI.Ideally,thesystemisoperatingat
135PSI+/5PSIandshownosignsof“creep”orinstabilityat3000PSI.
CautionNote:
“Creep”willshowastheIPsteadilyincreasingwhiletheregulatorisnotinuse.Normally
theIPwilldrop510PSIduringabreathorpurgeandthenreturntoitssetting.Itshould
notreturntothesettingandkeepincreasing.This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1ststage
withsomeexceptions.
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.
(6)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 will also require the unit to be rebuilt. Freshwater contains dissolved minerals and other
materialsthat,duetointernalcorrosionovertime,maycausetheregulatortomalfunction.
(7)AftertheIPhasbeenchecked,hosesandregulatorbodyinspected,andSPGevaluated,theserviceofthe
1ststagecantakeplaceifitisdeterminedthatserviceisnecessary.
 



4.FirstStageDisassembly
(1)1ststagedisassembly–Ensurethesystemisdepressurized.Documentthepositionofallhosesandport
plugs.Theuseofsmall,cleancontainerstoholdpartsisrecommended.
(2)Inthefollowingsteps,thepartnumbersfromtheschematicwillbeusedwiththeirdescription.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!
1.Removeallhosesandportplugs–Fig.7.

Fig.7
2.RemovetheDINShuttervalve(D2)usinga4mmhexandDINshuttercrown(D4),whichcontainstheSpring
(D6)andtwosmallnylonwashers(D5)–Fig.8.Washersarereplacedasindicatedbythe*symbol.

Fig.8
Thenumbersonthephotocorrespondwiththepartslistontheschematic.Thisisdonetoaidinthe
identificationofindividualitems.Itemsintheservicekitsareidentifiedinthesameway.
 



3.RemovetheRetainerHousing(D8)withthe4mmhexandlifttheDINHandwheeloffofthebody–Fig.9.

Fig.9
4.Insertthe1ststagehandleinto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visemayresultindamagetothe
bodythatwillrequirereplacementoftheregulator.Alwaysusea1ststagehandleto
securetheregulator.
 

5. Using a ¾ inch socket and ratchet loosen the Filter Retainer DIN (D10) – Fig. 11. Be sure to hold the socket
firmly so that it doesn’t slip. Use steady, even pressure. Remove the Retainer and Saddle (08).
Fig. 11
6. Carefully remove the orings from the DIN Shutter Valve, Retainer Housing, 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 the parts to be reused. The washers (D5)
will be replaced.
Fig. 12
Caution Note:
Take whatever steps are necessary for keeping track of items that are part of an
assembly. This degree of organization will reduce the risk of mistakes that can result in
a failure of the regulator.

7. Using the Multitool or Pin Spanner, 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 Seat
(31) – Fig. 15, (push out the HP seat with a blunt pick), remove Oring (32), Oring (30) and, Spring (29) – Fig.
16.
Fig. 15
9. Remove Oring 30 with a brass or nylon pick from its groove in the body of the regulator.
Fig. 16

10. Using the universal wrench or a pin spanner with an appropriate pin, and the 1st stage handle secure –
Fig. 17, loosen the End Cap (19) so that a gap is 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 (13), Washer (121), and Oring
(15) – Fig. 20.
Fig. 19 Fig. 20
12. Remove Oring 15, also using the pinch method to avoid scratching the piston sides – Fig. 21.
Fig. 21

13. Carefully remove the following components from the HP side of the regulator body. Washer (28), Oring
(27), and Teflon Washer (26) using 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 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)  Fig. 24.
Fig. 24
15. This allows access to the Washer (17). Remove the Washer. Pull the End Cap (19) from the Port Swivel
and remove the Washer (17) and Oring (20) from the Port Swivel – Fig. 25.
Fig. 25
This completes the disassembly of the 1st stage.

(3) The photographs below show 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
Fig. 27
1st Stage Service Kit

5. First 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.
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
2. Next, take the End Cap (19) and press it onto the Port Swivel (23) – Fig. 30. Install the other Washer (17),
as shown below. Install Nut (16) and torque this to 70 in lbs/81 kgf cm/8 Nm using a 6mm hex, and the 1st
stage handle installed in one of the open LP ports – Fig.31.
Fig. 30 Fig. 31

3. Set this assembly aside and install one of the Orings (27) into the groove on the regulator body that the
End Cap/Port Swivel assembly screws onto – Fig.32. Use the Piston Stem Bushing Assembly Tool and on the
narrower end place in the following order Washer (28), lubricated Oring (27), and Teflon Washer (26) – Fig.
33.
Fig. 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. Carefully slide the Piston Assembly into the End Cap/Port Swivel Assembly – Fig. 37. Using the previously
assembled Washer/Oring/Teflon Washer stack  Fig. 38, insert 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. 37 Fig. 38

6. Reverse the tool to hold the stack and protect the Piston end  Fig. 39. Insert the Piston/End Cap/Port
Swivel assembly into the regulator and screw it on hand tight  Fig. 40.
Fig. 39 Fig. 40
7. Install the 1st stage handle into a highpressure port  Fig. 41. Use the MultiTool to tighten the End Cap/Port
Swivel assembly to the body. A piece of rubber may be 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 the assembly aside and install the Oring (30) in the HP side of the body, as shown using the blunt brass
or plastic pick  Fig. 43. Install the Oring (32) onto the HP Seat Retainer and place the HP seat (31) into the
HP Seat Retainer. Orient the seat with the concave side towards the Piston and the flat side facing the HP
Seat Retainer  Fig. 44.
Fig. 43 Fig. 44