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).
C R Y S T A L
engineering corporation
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
C R Y S T A L
engineering corporation
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
C R Y S T A L
engineering corporation
Page 4 • GaugeCalXP Service Instruction Sheet
16 Remove the MPF-1/4FPT and MPM-MPM t-
tings from the Rear Gauge Base. Use a 5mm
Allen key to remove the four (4) cap screws
holding the Rear Gauge Base and its o-ring
(PN 4114 or 3130) from the top of the Manifold Block. Remove the o-rings (PN 3981)
from the MPF tting on both the Gauge Base
and the MPF-1/4FPT. Repeat for Front Gauge
Base.
MPF-1/4FNPT
MPM-MPM
MPF-GC
O-ring
(PN 4114 or 3130)
(1)
(1)
Internal O-rings
(PN 3981)
17 If the comparator is tted with an optional
Fine Adjust Kit, continue to step 18. If not,
you may skip ahead to step 24.
Note: A comparator without the Fine Adjust
option is instead tted with an Accessory
Cap, plus an o-ring that should be replaced.
The screws for the plate will require a 4mm
Allen key to remove. Screws included with
older Fine Adjust Kits will require a 5mm key,
while those included with recent, redesigned
kits will require a 4mm key.
18 Use either a 4- or 5mm Allen key to remove
the four (4) cap screws holding the Fine Adjust to the side of the Manifold Block, then
pull the Fine Adjust and its o-ring (PN 2018
or PN 3130) away from the Manifold Block
(gure 13).
Figure 12
Fine Adjust
Figure 13
O-ring
(PN 2018 or
PN 3130)
Fine Adjust
Knob
19 Use a 3mm Allen key to loosen the set screw
inside the Fine Adjust knob, then slide the
knob o of the piston (gure 14).
20 Use a 15mm box wrench to remove the Fine
Adjust bushing from the body, then slide the
bushing and its o-ring (PN 2018) o of the
piston (gure 15).
21 With the front of the Fine Adjust body facing
toward you, turn the piston clockwise until
the piston threads are clear of the hole in the
back of the Fine Adjust body (gure 16).
22 From the back of the Fine Adjust body, slide
out the piston (gure 17).
C R Y S T A L
engineering corporation
Figure 14
Figure 15
Fine Adjust
Bushing
*
O-ring
(PN 2018)
When reassembling, apply
*
Dow Corning 111 or a similar
silicone-based lubricant .
23 From the front of the Fine Adjust body,
remove the o-ring (PN 3129) and the backup
ring (PN 3150) (gure 18).
Note: The o-ring and backup ring may be
rmly seated in the Fine Adjust body. If so,
they can be extracted with a pair of tweezers
or other appropriate tool.
GaugeCalXP Service Instruction Sheet • Page 5
24 Use a 4mm Allen key to remove the four (4)
screws holding the Accessory Cap to the side
of the Manifold Block, then pull the cap and
its o-ring (PN 2018) away from the Manifold
Block (gure 19).
25 If the comparator is not tted with an
optional Fine Adjust, remove the second
Accessory Cap located on the other side of
the Manifold Block. Follow the procedure
outlined in step 24.
26 Clean all of the parts. Crystal recommends
you use an ultrasonic bath and a cleaning
solution that is compatible with the media
used in the unit.
In addition, we recommend that you use a
round brush to clean the piston hole in the
Manifold Block.
Fine Adjust Piston
Figure 16
Fine Adjust Piston
Figure 17
Backup ring
(PN 3150)
27 Reassemble the GaugeCalXP pressure com-
parator and optional Fine Adjust by following the preceding steps in reverse order.
Replace all o-rings, backup rings, and main
seal with those supplied in the rebuild kit.
Refer to the illustrated parts list on page 6.
Dow Corning® 111, or similar silicone-based
lubricants, are recommended for use on new
o-rings to ensure proper sealing.
When installing the gauge
bases, accessory caps, and ne
adjust; tighten the screws in the
order shown at right: rst to a
snug t, and then fully-torqued
to 85 in-lbs / 9.6 N-m.
1
3
List
4
2
Figure 18
Accessory
Cap
Figure 19
O-ring
(PN 2018)
O-ring
(PN 3129)
C R Y S T A L
engineering corporation
Page 6 • GaugeCalXP Service Instruction Sheet
Parts List
3129
6. 07mm x 1.7 8mm
0. 239in x 0. 070in
9. 25mm x 1.7 8mm
0. 364in x 0. 070in
Sizes to Scale
4165
QTY
1
9.52mm x 1.7 8mm
0.375in x 0. 070in
2018
4168
QTY
3981
6
1 2.42mm x 1.78mm
0.489i n x 0.07in
1 5.1mm x 2.7mm
0.594i n x 0.106in
QTY
4
4140
4114
4152
QTY
2
3131
4163
QTY
1
3130
4162
See the di mensions
for each o-r ing
Allen Keys
3176 - 3mm
3177 - 4mm
3178 - 5mm
Backup Rings
3150
3151
Rod Seal
3152 - Primary
3434 - Backup
3303 or 3376
4166 or 4167
2 1.82mm x 3.53mm
0.859i n x 0.139in
O-ring 3303 / 4166
34.65mm x 1. 78mm
1.364in x 0. 070in
O-ring 3376 / 4167
35mm x 2.5mm
1.378in x 0. 098in
2 1.94mm x 1.78mm
0.864i n x 0.070in
QTY
ea
1
Part Number:
Part Number:
Note:
1. The full-size o-ring diagrams may not
reproduce to scale when printed from
the pdf download.
2. All o-ring dimensions provide rst the
inside diameter, then the thickness.
QTY
3
3418
4169
QTY
1
Standard
Skydrol compatible
GaugeCalXP Service Instruction Sheet • Page 7
Routine Flushing
If a complete rebuild is not required, ushing the GaugeCalXP can serve as a quick and simple way
to remove small amounts of dirt or sediment from the system. Flushing can also be used to ensure
that any air is removed from the system prior to performing a calibration test. Flushing the unit
should never serve as a substitute for a rebuild; and remember that any service beyond a routine
ush should always be performed by a qualied technician.
Flushing Instructions
1 Remove all gauges from the GaugeCalXP pressure comparator.
2 To completely open the reservoir, wind the handle counter-clockwise until you feel it stop.
3 Securely grip the front of the Baseplate (near the bearing block) and lift to tip the GaugeCalXP
on its end. Any uid in the system will run out through the rear Gauge Base port.
4 Set the unit back down, at on the Baseplate, and begin to pour warm soapy water or clean
hydraulic oil into the reservoir. Continue to ll the unit until the uid begins to run out of the
Gauge Base ports. Always dispose of uids in a responsible manner.
5 Once again, tip the GaugeCalXP on its end until all of the uid in the system has drained out.
6 Set the unit back down, then wind the handle clockwise at least 10 turns, then ll the reservoir
with test uid to within 6mm (1/4") from the top.
7 Follow the operator instructions supplied with your GaugeCalXP to ll the system and begin
calibration testing.
CAUTION: Solvents can damage o-rings and should never be used when ushing or otherwise
cleaning the GaugeCalXP.
How to Contact Us:
Phone (805) 595-5477
Toll-Free (800) 444-1850
Fax (805) 595-5466
Email service@crystalengineering.net
Web www.crystalengineering.net
Send your comments to: feedback@crystalengineering.net
C R Y S T A L
engineering corporation
C R Y S T A L
engineering corporation
© 2010 Cr ystal Engineering Corporation
708 Fiero Lane, Suite 9, San Luis Obispo, California 93401-8701
PN 4139 Rev C
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