Crystal GaugeCalXP Rebuild Kit User Manual
g
lxp
250
100
DESIGNED FOR USE WITH CRYSTAL PRESSURE FITTINGS
™
PRESSURE COMPARATOR
Gau
eCa
10000 PSI–700bar
Service Instruction Sheet
Introduction
These instructions are intended for use with standard comparator rebuild kit (PN 4138) or the
Skydrol rebuild kit (PN 4158). Both rebuild kits contain all of the parts and tools required to rebuild
the GaugeCalXP™ pressure comparator. Rebuilds should be performed only by qualied personnel.
Following service instructions are for the standard comparator rebuild kit (PN 4138). If rebuilding the Skydrol
GaugeCalXP, cross reference the appropriate o-ring part numbers in the Parts List located on the last page.
Service Instructions
1 Remove all gauges and ttings from the
GaugeCalXP pressure comparator (gure 1).
2 Tip the comparator on its end to completely
drain the water or oil from the system.
Always dispose of uids in a responsible
manner.
3 Use a 3mm Allen key to remove the two (2)
cap screws securing the Reservoir to the
Main Seal Block, then lift to remove the Reservoir and Reservoir o-ring (PN 2018)
(gure 2).
4 Remove the press-t Reservoir Vessel,
and replace the lower seal o-ring (PN 3303
or PN 3376) (gure 2).
Note:The GaugeCalXP is assembled with
*
a Reservoir o-ring in one of two sizes. Compare your o-ring to the illustrated parts list
on page 6, to determine the appropriate
replacement size for your unit.
Gauge
Base
Figure 1
Figure 2
O-ring
Reservoir
(PN 2018)
O-ring
(PN 3303)
or
(PN 3376)
50
0 300
*
PSI
5 Use a 4- or 5mm Allen key to remove the
Handle Assembly bolt and washer(s), then
pull to slide the Handle Assembly from the
Piston Assembly (gure 3). Be sure to also
remove the Key from the Piston Assembly
Leadscrew (gure 3).
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Figure 3
Leadscrew
Handle
Key
Page 2 • GaugeCalXP Service Instruction Sheet
6 Turn the comparator over to gain access to
the underside of the Baseplate.
Be aware that water or other test uid may
still be present in the system, and may drain
out as the comparator is turned over.
7 Use a 4mm Allen key to remove the two (2)
cap screws holding the Bearing Block to the
Baseplate (gure 4).
Bearing Block
Baseplate
8 Turn the comparator back over, and then use
a 5mm Allen key to remove the three (3) cap
screws from the front of the Bearing Block
(gure 5).
9 Carefully pull to slide the Bearing Block and
Piston Assembly from the Manifold Block
and Baseplate, taking care to avoid making
contact with the three guide rods (gure 6).
10 Pull to slide the Piston Assembly from the
rear of the Bearing Block, and then remove
the Bearing Ring and Bearing Washer from
the front of the Leadscrew (gure 7).
Note: A Bearing Ring may stay inside the
Bearing Block. Please note the correct
orientation of the Bearing Rings in relation
to the Bearing itself. The correct orientation
is the “open” side of the Bearing faces the
Wide Channel Bearing Ring . The “closed”
side faces the Narrow Channel Bearing Ring.
This will center the Bearing between the two
rings.
11 Unscrew the Piston Shaft from the Piston
Assembly for cleaning, and then apply a
light coat of multi-purpose lithium base
grease before reassembling
(gure 8).
Note: The Piston Shaft has a left-hand
thread, so you will turn it clockwise to
remove it, and then counter-clockwise to
replace it.
Figure 4
Figure 5
Guide
Rod
Piston
Assembly
Figure 6
Wide
Channel
Bearing
Ring
Leadscrew
Bearing
Narrow
Channel
Bearing
Ring
Figure 7
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12 To remove the three (3) stainless steel Guide
Rods, insert the 4mm Allen key into the hole
in the side of each rod, and then pull to the
left (counter-clockwise) to loosen and unscrew each one (gure 9).
When the nal Guide Rod has been removed, the Main Seal Block will fall away
from the Manifold Block.
GaugeCalXP Service Instruction Sheet • Page 3
Piston
Shaft
13 From the front of the Main Seal Block,
remove the o-ring (PN 3131) and the backup ring (PN 3151) (gure 10).
14 From the rear of the Main Seal Block, remove
the Rod Seal (PN 3152) and Rod Seal Backup
(PN 3434) (gure 10).
Note: When rebuilding the Main Seal Block
assembly, Dow Corning® 111, or a similar
silicone-based lubricant, must be applied
to the grooved surface of the Rod Seal (PN
3152).
When the Rod Seal is installed, its at surface should face toward the Main Seal Block,
while its grooved surface faces out to mate
with the Manifold Block (gure 10).
15 From the front of the Manifold Block,
remove the Main Seal Block o-ring (PN 3418)
(gure 11).
Note: When re-attaching the Main Seal
Block and Guide Rods to the Manifold Block,
you may nd it easier to rst remove the
Manifold Block from the Baseplate.
From the underside of the Baseplate, use a
4mm Allen key to remove the four (4) cap
screws holding the Manifold Block in place.
Use the three (3) Guide Rods to attach the
Main Seal Block to the Manifold Block, then
re-attach the Manifold Block to the Baseplate before attaching the Piston Assembly
and Bearing Block.
Figure 8
Figure 9
Rod Seal
(PN 3152)
Rod Seal Backup
(PN 3434)
Rod Seal and
Backup shown
rotated 90°
Figure 10
O-ring
Guide Rod
Main Seal
Block
(PN 3131)
Backup ring
(PN 3151)
O-ring
(PN 3418)
Figure 11
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