Oceanic DX1 User manual

REGULATORS
DXIINTEGRATED FIRST STAGE
© 2002 Design 2000 OCEANICOCEANIC
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TROUBLE SHOOTING
SYMPTOM POSSIBLECAUSE TREATMENT
* Restricted airflow and
inhalationresistance through
complete system.
* Air leakage detected from
beneath the adjustment cup,
inside the end cap.
* Air leakage detected from
receiver.
* Insufficient intermediate
pressure.
* Excessive intermediate pres-
sure/Intermediate pressure
creeps.
1.Cylinder valve not completely
opened.
2.Cylinder valve requires service.
3.Cone filter(4,13) is contami-
nated.
1.Transmitter o-ring(23, 24) is
damaged or worn.
2.Seating surface inside the
body(28) is damaged.
3.Seating surface on the transmit-
ter(22) is damaged.
1.End cap(32,37) is loose.
2.First stage improperly
adjusted.
3.Ambient spring(33) is weak-
ened or damaged.
4.Seating surface of body(28)
beneath diaphragm is
damaged.
1.First stage improperly adjusted.
2.HP seat(27) is damaged or worn.
3.HP seat o-ring(25) is damaged
or worn.
4.Seating surface of HP seat(27),
or transmitter(22), or main body
orifice cone, or body(28) is
damaged.
5.Seat spring(26) is weakened or
damaged.
1.Open valve completely.
2.Connect regulator to a
different cylinder.
3.Replace with new and
perform a complete service.
1.Tighten end cap onto body,
using prescribed torque
value in reassembly proce-
dure.
2.Replace with new.
3.Replace body with new.
1.Replace with new.
2. Replace with new.
3. Replace with new.
1.Tighten end cap onto body,
using prescribed torque value
in reassembly procedure.
2.Readjust according to
procedure specified in final
adjustment procedure.
3.Replace with new.
4.Replace body with new.
1.Readjust according to final
adjustment procedure.
2.Replace with new.
3.Replace with new.
4.Replace with new.
5.Replace with new.
1.End cap(32,37) is loose.
2.Diaphragm(30) is worn or
damaged.
3.Seating surface inside
body(28) is damaged.

REGULATORS
DXIINTEGRATED FIRST STAGE
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Fig. 2
DISASSEMBLY PROCEDURE
NOTE: Besuretocheckandrecordtheintermediatepressure
and perform the Leak Detection Test outlined in the Initial
InspectionProceduresprior todisassemblingtheregulator.
Review the troubleshooting section to gain a better idea of
which internal parts may be worn, and to better advise your
customeroftheservicethatisneeded.
1. Before disassembling the first stage, remove the low pressure
second stage hoses with a 9/16" open end wrench, the high
pressure hose(s) with a 5/8" open end wrench, and the low
pressureinflatorhosewitheithera9/16"or1/2"openendwrench.
2. Removeandinspecttheo-ringsnowvisibleonalltheseitemsfor
any signs of decay. Discard if found.
NOTE: It is important to remove the transmitter(22) end
componentsfirsttoavoiddamageoftheHPseatconelocated
inside the main body.
3. Securethefirststageinasoft-jawedorwellpaddedviseandapply
a 3/8" socket drive wrench with a DX Spanner(40.6536) to the
Transmitter assembly(22). Turn the Transmitter assembly in a
counter clockwise direction to remove it from the body (28).
(Fig.1)
CAUTION: Tighten the vise only as needed to hold the first
stagesecure,andDONOTovertighten. Doingsowillresultin
permanentdamage,rendering it inoperable.
4. RemovetheHPseat(27)fromthetransmitter(22). DiscardtheHP
seat, regardless of condition, and DO NOT attempt to reuse.
5. Remove the HP seat spring(26). Using a magnifier, closely
examinethespring(26)foranysignsofcorrosion,cracks,orother
damage. Discard if found and DO NOT attempt to reuse.
6. Using care not to scratch or damage the transmitter assembly,
removetheHPseato-ring(25)frominsidethetransmitterassem-
bly(22). Discard,regardlessofcondition,andDONOTattemptto
reuse. (Fig. 2)
7. Removeandinspectthetransmittero-rings(23,24)foranysigns
of decay. Discard if found.
8. With the use of a penlight and a magnifier, closely examine the
seating surface of the orifice cone inside the main body for any
signs of damage. If found, discard the main body and DO NOT
attempt to repair or reuse. (Fig. 3)
NOTE: Performstep9 onlyifanEnvironmentalProtectionKit
hasbeeninstalled.
Fig. 1
Fig. 3

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9. Environmental Protection Kit Disassembly:
A. Turn the plastic environmental cap(40) counter clockwise by
handtoloosenand remove.
B. Gentlypeelthe lip oftheenvironmental diaphragm(39) away
from the rim of the end cap(37) and lift out to remove. (Fig.4)
Examinetheconditionofthediaphragm,checkingforanysignsof
wear, distortion, corrosion, or perforation. Discard if found.
C. Turn the first stage diaphragm side down and remove the
transfer piston(38). Check for any signs of wear, distortion, or
corrosion. Discard if found.
NOTE: Performstep10ifanEnvironmentalProtectionKithas
notbeen installed.
10. Lift the end cap boot(36) away from the end cap(32) using your
fingers. DO NOT use tools.
11. Using a 5/16" hex key, turn the adjustment cup(35), counter
clockwise to remove. (Fig. 5)
12. Remove the spring washer(34) and spring(33). Inspect the
washer(34) for any signs of wear or distortion. Discard if found.
13. Usingamagnifier,closely inspectthe spring(33)for any signs of
corrosion,cracks,orotherdamage. DiscardiffoundandDONOT
attempt to reuse.
14. Securethefirststageinasoft-jawedorwellpaddedviseandapply
a 3/8" socket drive wrench with CDx Spanner to the end cap(32
or 37). Turn the end cap counter clockwise to remove from the
mainbody(28). (Fig.6) Liftoutthespringpad(31),andinspectfor
signs of wear or distortion. Discard if found.
CAUTION: Tighten the vise only as needed to hold the first
stagesecure,andDONOTovertighten. Doingsowillresultin
permanentdamage,rendering it inoperable.
15. Usinga5/32" hex key, install HP portplugs(18)intotheopenHP
ports,andLPportplugs(20)intoallbutoneoftheLPports. Check
to ensure that 1 of the 4 LP ports is open, and all other ports are
sealed. Tightentheyokescrewtoensurethattheprotectorcap(8)
is securely sealed over the yoke retainer(6). For DIN models,
placetheprotectorcap(8)securelyoverthefilterretainer(10)and
DINcouplerwheel(12).
CAUTION: DONOTattempttoremovethediaphragm(30)with
the use of a metallic instrument. Doing so will seriously
damagethebrassseatingsurface of the body.
Fig. 5
Fig. 6
Fig. 4

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16. Removethediaphragm(30) from themain body(28) by covering
thetransmitteropeninginthebodywiththepalmofyourhandand
directingshortblastsoflowpressureairthroughtheopenLPport.
(Fig.7) Liftthediaphragmoutcarefullyanddiscard,regardlessof
its condition, and DO NOT attempt to reuse.
17 Remove the button-pin(29) and inspect for signs of wear or
distortion. Discard if found.
18. Removeallportplugs(18&20)witha5/32"hexkey. Removeand
inspect the port plug o-rings(19 & 21) for any signs of decay.
Discard if found.
NOTE: ForunitsreceivedwithYokeconnectorsperformstep
19Y,forunitsreceivedwithDINconnectorsperformstep19D.
19Y. Yoke connector disassembly:
A. Removethe knobassembly(1) fromthe yoke(2)
B. Securethefirststagebody(28)inasoftjawedorwellpadded
vise and apply a thin wall, or modified, 1" box wrench to the yoke
retainer(6). Usingfirmsteadyforce,turntheyokeretainercounter
clockwise to remove. DO NOT use impact to loosen.
NOTE: Itisimportantthatthewrenchisproperlyseatedover
the entire hex portion of the yoke retainer to prevent any
damage to the part. (Fig. 8)
CAUTION: Tighten the vise only as needed to hold the first
stagesecure,andDONOTovertighten. Doingsowillresultin
permanentdamage,rendering it inoperable.
C. After removing the yoke retainer(6), remove the yoke(2)
protectorcap(8),andsaddle(17)andsettheseaside. Removeand
discard the yoke retainer o-ring(7). DO NOT attempt to reuse.
D. Using Internal Circlip Pliers, remove the retaining clip(3) that
retainstheconefilter(4). Theconefiltershoulddropoutfreelyinto
yourhand. Discard,andDONOTattempttoreuse. Removeand
inspectthefiltero-ring(5) for anysignsofdecay. Discard if found
19D. DIN connector disassembly:
A. Securethefirststageinasoft-jawedorwellpaddedvise,with
the DIN connector facing up. Apply a 1/4" hex key to the filter
retainer(10)andlooseninacounterclockwisedirectiontoremove.
(Fig.9) RemovetheDINfaceo-ring(9)andfilterretainero-ring(11)
and inspect for any signs of decay. Discard if found.
CAUTION: Tighten the vise only as needed to hold the first
stagesecure,andDONOTovertighten. Doingsowillresultin
permanentdamage,rendering it inoperable.
Fig. 8
Fig. 7
Fig. 9

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B. Liftthecouplerwheel(12)straightoffthefilterhousing(15)and
set aside. Remove the protector cap(8) and set aside. Apply a
13\16" open end wrench to the flange at the base of the filter
housing(15). (Fig.10) Usingfirm,steadyforce,looseninacounter
clockwise direction to remove. DO NOT use impact to loosen.
NOTE: Itis importantthatthe wrenchisdeepenoughtoseat
entirely over the flange to avoid any damage to the seating
surface.
C. Afterremovingthefilterhousing(15)fromthemain body(28),
turnitoverandtaplightlytodropouttheconicalfilter(13). Discard
the filter and DO NOT attempt to reuse. Remove and inspect the
filtero-ring(14)forany signs ofdecay. Discardiffound. Remove
anddiscardDINfilterhousingo-ring(16). DONOTattempttoreuse.
20. Inspect the saddle(17), checking for any signs of damage or
distortion. Discard if found.
REASSEMBLY PROCEDURE
NOTE: Priortoreassembly,itisnecessarytoinspectallparts,
bothnewandthosethatarebeingreused. Checktoensurethat
o-ringsarecleanandsupple,andthateverypartandcompo-
nenthasbeen thoroughlycleaned.
WARNING: UseonlygenuineOceanicparts,subassemblies,
and components whenever assembling Oceanic products.
DO NOT attempt to substitute an Oceanic part with another
manufacturer’s,regardlessofanysimilarityinshape,size,or
appearance. Doing so may render the product unsafe, and
could result in serious injury or death of the user.
NOTE: ForunitsreceivedwithYokeconnectorsperformstep
1Y, for units received with DIN connectors perform step 1D.
1Y. Yoke connector reassembly:
A. Installthefilter o-ring(5)intothe yokeretainer(6), at thebase
of the filter cavity in the body. (Fig. 11)
B. Install the conical filter(4) into the yoke retainer(6) and install
theretainingclip(3)intothegrooveaboveit,usingInternalCirclip
Pliers. (Fig. 12)
NOTE: Closeexamination oftheretainingclipwillshowthat
one side is slightly rounded and the other is flat. Install with
the flat side facing out of the yoke retainer to ensure greater
holdingstrength.
C. Lubricateandinstall theyokeretainero-ring(7)intothegroove
on the end.
Fig. 11
Fig. 10
Fig. 12

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D. Insert the threaded end of the yoke retainer(6) through the
yoke(2),facingoppositetheendwhichholdstheknobassembly(1).
Place the protector cap(8) and the saddle(17) onto the yoke
retainer(6),withtheflatsidematingtothebaseoftheyoke.(Fig.13)
E. Securethefirststagebodyinasoftjawedorwellpaddedvise,
with the threaded HP inlet bore facing straight up.
CAUTION: Tighten the vise only as needed to hold the first
stagesecure,andDONOTovertighten. Doingsowillresultin
permanentdamage,rendering it inoperable.
F. Holdingtheyokeretainer,yoke,dustcap,andsaddletogether
betweenthumbandforefinger, matetheyokeretainerintothemain
body,sothatthethreadsseatproperly. Handtighteninaclockwise
direction until secure. (Fig. 14) Using a thin-wall, or modified, 1"
crow'sfootwrenchthatisproperlyseatedovertheentirehexportion
of the retainer, tighten to a torque of 16-18 ft-lbs.
G. Install the knob assembly(1) into the yoke(2).
1D. DINconnectorreassembly:
A. Lubricate and install the DIN filter housing o-ring(16) into the
groove on the end of the DIN filter housing(15).
B. Insertthethreadedendofthefilterhousing(15)throughtheflat
sideof the saddle(17).
C. Securethefirststagebodyinasoftjawedorwellpaddedvise,
with the threaded HP inlet bore facing straight up.
CAUTION: Tighten the vise only as needed to hold the first
stagesecure,andDONOTovertighten. Doingsowillresultin
permanentdamage,rendering it inoperable.
D. Installthefilterhousing(15)intothemainbody(28)sothatthe
threadsseatproperly,andhandtighteninaclockwisedirectionuntil
secure. Usingathin-wall,ormodified13/16"crowsfootwrenchthat
is properly seated over the entire seating surface of the filter
housing flange, tighten to a torque of 16-18 ft-lbs. (Fig. 15)
E. Lubricate and install the conical filter o-ring(14) into the filter
housing(15), at the base of the filter cavity. Install the conical
filter(13) into the filter housing.
F. Installtheprotectorcap(8)andthecouplerwheel(12)downover
thestemofthefilterhousing(15),withthethreadedendfacingup.
G. LubricateandinstalltheDINfaceo-ring(9)andfilterretainero-
ring(11)ontothefilterretainer(10).
Fig. 14
Fig. 13
Fig. 15

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H. Insert the threaded end of the filter retainer(10) through the
coupler wheel(12), into the filter housing(15), and tighten until
secure. Apply a 1/4" hex socket and tighten to a torque of 120-
140in-lbs.
2. Place the stem of the button-pin(29) directly into the center hole
in the body(28), ensuring that it enters without any restriction.
(Fig.16)
3. Position the diaphragm(30) flat, directly over the opening of the
body(28). Gentlypushtheedgesofthediaphragmdowninsidethe
internalthreadsofthebody,onethreadatatime. Rotatethebody
whiledoingthis,tofacilitateanevenseatingofthediaphragm,and
closely inspect to ensure it is well seated at the base of the
threads. (Fig. 17)
CAUTION: DONOTforcethediaphragm(30)intothebody(28)
in a manner that will damage either the lip or surface of the
diaphragm, or the threads of the body. The use of a sharp
instrument, such as a screwdriver, is to be strictly avoided.
4. Laythespringpad(31)ontothecenterofthediaphragm(30),with
its flat surface against the diaphragm(30).
5. Threadtheendcap(32or37),intothebody(28),turningclockwise
by hand until secure.
6. Securethefirststagebodyinasoftjawedorwellpaddedvise,and
usingCDxSpannerandafoot-poundstorquewrench,tightenthe
end cap(32 or 37), into the body to a torque of 30-38 ft-lbs.
(Fig.18)
CAUTION: Tighten the vise only as needed to hold the first
stagesecure,andDONOTovertighten. Doingsowillresultin
permanentdamage,rendering it inoperable.
7. Apply a very light film of lubricant (Christo- Lube MCG #111) to
bothendsofthediaphragmspring(33),andplaceitonthespring
pad(31).
8. Place the spring washer(34) directly onto the upper end of the
spring(33)andinstalltheadjustmentcup(35)intotheendcap(32
or 37). Using a 5/16" hex key, turn the adjustment cup(35)
clockwise until only two threads are showing.
9. Lightlylubricateandinstallthetransmittero-rings(23,24)ontothe
transmitter(22)andtheHPseato-ring(25)intotheinnerboreofthe
transmitter. Lightly lubricate the threads of the transmitter(22).
10. Apply a very light film of lubricant to both ends of the HP seat
spring(26)andthelower1/4"oftheHPseatshaft(27). Installthe
HP seat spring(26) onto the end of the transmitter(22).
Fig. 17
Fig. 16
Fig. 18

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11. Carefully guide the shaft of the HP seat(27) so that it passes
throughthespring(26)andintotheseato-ring(25)intheinnerbore
of the transmitter(22). (Fig. 19)
12. Holdthebody(28)ataslightangle,sothatyoumayseethe stem
end of the button-pin(29) protruding through the center of the
machined orifice cone. Insert the transmitter/hp seat assembly
directlyintothecenteroftheopeninginthebody(28)andcarefully
guidethecenteropeningoftheHPseat(27)ontothebuttonpin(29).
Ensurethebutton-pin(29)entersdirectlyintotheopeningoftheHP
seat(27)withoutanyrestriction.(Fig.20)
CAUTION: Improper alignment of the button-pin(29) and the
HP seat(27) during installation will result in damage to the
seatingsurfaceoftheHPseat(27),requiringitsreplacement.
13. Whileholdingthebody(28)secure,turntheTransmitter/HPseat
assembly clockwise while exerting continuous inward force to
overcome spring pressure and engage the threads. Continue
tightening by hand until secure.
14. Secure the first stage body in a soft jawed or well padded vise.
UsingaCDxSpanneronaninch-poundstorquewrench,tightenthe
Transmitterassembly(22) into the body to a torque of 80 to 100
in-lbs. (Fig. 21)
CAUTION: Tighten the vise only as needed to hold the first
stagesecure,andDONOTovertighten. Doingsowillresultin
permanentdamage,rendering it inoperable.
15. Lubricate and install port plug o-rings(19 & 21) onto the port
plugs(18 & 20) and install the port plugs into the body(28),
tighteningclockwisewitha5/32"hexkeysockettoatorqueof35-
40 in-lbs.
16. Lubricate and install all hose o-rings onto hoses and install the
hosesinto thebody(28). Tighten the low pressure secondstage
hose(s) clockwise with a 9/16" crows foot wrench, the high
pressure hose(s) with a 5/8" crows foot wrench, and the low
pressure inflator hose(s) with either a 9/16" or 1/2" crows foot
wrench, to a torque of 35-40 in-lbs.
CAUTION: Becertainnottoinstallanylowpressurehoseinto
a high pressure port via an adaptor.
NOTE: Performstep17onlyifanEnvironmentalProtectionKit
hasNOT been installed.
17. Ensuringproperalignmentandsecureplacement,installtheend
capboot(36)ontotheendcap(32).
Fig. 20
Fig. 19
Fig. 21

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FINAL ADJUSTMENT
1. Connect a recently calibrated low pressure test gauge to a low
pressurehose,andconnectthefirststagewithsecondstageand
low pressure test gauge to a pure breathing gas source of 3000
PSI. Slowlyopenthesupplyvalvetopressurizetheregulator,and
purge the second stage several times.
2. Adjust the intermediate pressure, if necessary, to read 142-148
PSI by turning the adjustment cup(35) clockwise to increase the
pressure or counter clockwise to decrease it. (Fig. 22)
NOTE: Turntheadjustmentcup no morethan1/8ofa turn at
atime,pausingtopurgethesecondstageseveraltimestogain
an accurate reading of the intermediate pressure before ad-
justingfurther.
NOTE: Ensurethattheintermediatepressureholdsstableat
142-148PSI,anddoes notcreeporfluctuateafter thesecond
stagehasbeenpurgedseveraltimes. Ifcreepingisdetected,
refer to the troubleshooting section to determine possible
causeandtreatment.
NOTE: Performthefollowing stepsonlyifan Environmental
Protection Kit is being installed.
ENVIRONMENTAL KIT REASSEMBLY
1. Insertthetransferpiston(38)intotheenvironmentalendcap(37).
(Fig.23)
2. Turntheairsupplyoffandbleedoffintermediatepressure. Insert
theenvironmentaldiaphragm(39)overthetopoftheendcap(37)
with the thin perimeter seal facing down. Ensure that the thin
perimetersealisseatedcompletelyintothecirculargrooveinthe
environmentalendcap(37). (Fig.24)
3. Thread the plastic environmental cap(40) onto the end cap(37),
beingverycarefultoavoidcrossthreading,andtightenclockwise
by hand until secure. DO NOT use tools to tighten.
4. Turnontheairsupplyandpurgethesecondstageseveraltimes,
andcheck once more to ensure proper intermediate pressure of
142-148psi.
Fig. 23
Fig. 22
Fig. 24

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Specialty Tools
P/N 40.2302 Christo-Lube MCG111 - 2 oz
P/N 40.6536 3/8" socket drive CDx Spanner
P/N 40.9311 Filter Circlip Pliers
P/N 40.9313 5/32" Allen Key
P/N 40.9314 5/16" Allen Key
P/N 40.9315 Intermediate Press. Gauge
P/N 40.9320 1/4" Allen Key (for DIN model)
P/N 40.9520 O-ring Tool Kit
Torques
P/N 6564 Yoke Retainer 16 to 18 ft-lbs
P/N 4544 DIN Filter Retainer 120 to 140 in-lbs
P/N 6565 DIN Filter Housing 16 to 18 ft-lbs
P/N 3462 HP Port Plug 35 to 40 in-lbs
P/N 3463 LP Port Plug 35 to 40 in-lbs
P/N 6580 End cap 30 to 38 ft-lbs
P/N 6583 Environ. End Cap 30 to 38 ft-lbs
P/N 6586 Transmitter Asm 80 to 100 in-lbs
HP Hose into First Stage Body 35 to 40 in-lbs
LP Hose into First Stage Body 35 to 40 in-lbs
Inflator Hose into First Stage Body 35 to 40 in-lbs
Intermediate Pressure
Prefered 142 to 148 psi
Acceptable 139 to 151 psi
SPECIFICATIONS