Dive Gear Express XTRA Second Stage Manuel utilisateur

DGX Gears XTRA Regulator

Service Manual

DGX Xtra Second Stage

Author/Photographer – UDM Consulting

Rev.5c 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all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.Itwillshowupasglowinglinesorfragments.Ifanyarepresent,thepartneedstobere

cleanedanddried!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thewaterandcirculatethewateraroundthem.Allowthe

piecestosoakforseveralminutesandthewatertosettle.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.



(29)Maintainingoxygencleanconditionsfor2ndstagesistechnicallynotmandatory.The2ndstageisalow

pressuredeviceoperatingat135psi.Regardless,bestpracticeistomaintainoxygencleanconditionsalong

withtheexclusiveuseofoxygencompatiblelubricantswhenservicingtheregulator.



Thenextsectionliststhetoolsyouwillneedtoservicetheregulator.

 

2.TOOLLIST



(1)Thetoollistforthesecondstageisnotasextensiveasthatforthefirststage.Theyarestilldividedinto

RequiredandRecommended.The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Fig.3

1. 2AdjustableWrenches(thinjawed)orthin11/16wrenchandproperwrenchforLPhose

2. 3/16thhexwrench

3. Brass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purchasetoolsfromDiveGearExpress.TheInLineAdjustingToolwithIPgauge,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

Magnehelic

 

3.PreliminaryTesting

(4)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!

(5)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.

(6)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.Itisalsoaclearindicationthatthesecondstage

requiresrebuildingifturningtheadjustmentknobdoesnotstoptheflow.

(7)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.

(8)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.

(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 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.

(10)AftertheIPhasbeenchecked,hosesandregulatorbodyinspected,andSPGevaluated,thesecondstage

inspectioncantakeplace.Itisnecessarytoperformaninspectionofthe1ststageandchecktheintermediate

pressure.Intermediatepressurehasadirectbearingontheperformanceofthesecondstage.IncorrectIP

cangivefalseindicationsastothelevelofservicerequiredonthesecondstage.

CautionNote:

Itmaybenecessarytoservicethesecondstagewhenthe1ststagedoesnotrequire

service.Allinspectionstepsandevaluationsshouldbedonetoensureproperoperationof

theentireassembly.

 

Table des matières

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