Crystal GaugeCaLXP User manual

Service Instruction Sheet
Introduction
These instructions are intended for use with comparator rebuild kit (PN 3143) and with the fine
adjust kit (PN 3205). Rebuild kit 3143 contains all of the parts and tools required to rebuild the
GaugeCalXP™ pressure comparator, while kit 3205 contains the parts and tools required to install
the optional fine adjust. Rebuilds and installation should be performed only by qualified personnel.
Service Instructions
1 Remove all gauges from the GaugeCalXP
pressure comparator.
2 Remove any gauge or stem adapters from
both the flange stem and gauge base.
(figure 1).
3 Tip the comparator on its end to completely
drain the water, oil, or isopropyl alcohol from
the system. Always dispose of fluids in a
responsible manner.
4 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 Res-
ervoir and Reservoir o-ring (PN 1959)
(figure 2).
5 Remove the press-fit Reservoir Vessel, and
replace the lower seal o-ring (PN 3033)
(figure 2).
6 Use a 5mm Allen key to remove the Handle
Assembly cap screw and washer, then pull to
slide the Handle Assembly from the Piston
Assembly (figure 3). Be sure to also remove
the Key from the Piston Assembly Leadscrew
(figure 3).
PRESSURE COMPARATOR
10000PSI–700bar
GauGeCaLXP™
Figure 1
Figure 2
Figure 3
C R Y S T A L
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Page 2 • GaugeCalXP Service Instruction Sheet
C R Y S T A L
engineering corporation
7 Turn the comparator over to gain access to
the underside of the Baseplate.
Be aware that water or other test fluid may
still be present in the system, and may drain
out as the comparator is turned over.
8 Use a 4mm Allen key to remove the two (2)
cap screws holding the End Block to the
Baseplate (figure 4).
9 Turn the comparator back over, and then
use a 5mm Allen key to remove the three (3)
cap screws from the front of the End Block
(figure 5).
10 Carefully pull to slide the End Block and
Piston Assembly from the Manifold Block
and Baseplate (figure 6).
11 Pull to slide the Piston Assembly from the
rear of the End Block, and then remove the
Bearing Ring and Washer from the front of
the Leadscrew (figure 7).
12 Unscrew the Piston Shaft from the Piston
Assembly for cleaning, and then apply a
light coat of grease before reassembling
(figure 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
Figure 6
Figure 7

GaugeCalXP Service Instruction Sheet • Page 3
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13 To remove the three (3) stainless steel Guide
Rods, insert an 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 (figure 9).
When the final Guide Rod has been re-
moved, the Main Seal Block will fall away
from the Manifold Block.
14 From the front of the Main Seal Block, re-
move first the o-ring (PN 3132) and then the
backup ring (PN 3151) (figure 10).
15 From the rear of the Main Seal Block, remove
the Rod Seal (PN 3152) (figure 10).
Note: When rebuilding the Main Seal Block
assembly, Dow Corning® 111, or a similar sili-
cone-based lubricant, must be applied to the
grooved surface of the Rod Seal (PN 3152).
When the Rod Seal is installed, its flat sur-
face should face toward the Main Seal Block,
while its grooved surface faces out to mate
with the Manifold Block (figure 10).
16 From the front of the Manifold Block, remove
the Rod Seal o-ring (PN 3131) (figure 11).
Note: When re-attaching the Main Seal
Block and Guide Rods to the Manifold Block,
you may find it easier to first remove the
Manifold Block from the Baseplate. From the
underside of the Baseplate, use a 5mm Allen
key to remove the four (4) cap screws hold-
ing 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 at-
taching the Piston Assembly and End Block.
Figure 8
Figure 9
Figure 10
Figure 11

Page 4 • GaugeCalXP Service Instruction Sheet
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17 Use a 5mm Allen key to remove the four (4)
cap screws holding the rear Gauge Base to
the top of the Manifold Block, then lift the
Gauge Base and its o-ring (PN 3130) from the
Manifold Block (figure 12).
18 Remove the forward Gauge Base by follow-
ing the procedure outlined in step 16.
If the comparator is fitted with an optional
Fine Adjust Kit, continue to step 19. If not,
you may skip ahead to step 25.
Note: A comparator without the Fine Adjust
option is instead fitted 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.
19 Use either a 4- or 5mm Allen key to remove
the four (4) cap screws holding the Fine Ad-
just to the side of the Manifold Block, then
pull the Fine Adjust and its o-ring (PN 1734)
away from the Manifold Block (figure 13).
20 Use a 3mm Allen key to loosen the set screw
inside the Fine Adjust knob, then slide the
knob off of the piston (figure 14).
21 Use a 15mm box wrench to remove the Fine
Adjust bushing from the body, then slide the
bushing and its o-ring (PN 1959) off of the
piston (figure 15).
22 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 (figure 16).
Figure 12
Figure 13
Figure 14
Figure 15

GaugeCalXP Service Instruction Sheet • Page 5
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23 From the back of the Fine Adjust body, slide
out the piston (figure 17).
24 From the front of the Fine Adjust body,
remove the o-ring (PN 3129) and the backup
ring (PN 3150) (figure 18).
Note: The o-ring and backup ring may be
firmly seated in the Fine Adjust body. If so,
they can be extracted with a pair of tweezers
or other appropriate tool.
25 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 1734) away from the Manifold
Block (figure 19).
26 If the comparator is not fitted 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 25.
27 Clean all of the parts. Crystal recommends
you use an ultrasonic bath and an appropri-
ate cleaning solution.
In addition, we recommend that you use a
round brush to clean the piston hole in the
Manifold Block.
28 Reassemble the GaugeCalXP pressure com-
parator and optional Fine Adjust by follow-
ing 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.
Figure 16
Figure 17
Figure 18
Figure 19

Page 6 • GaugeCalXP Service Instruction Sheet
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3143 Parts List
3205 Parts List
3133 Fine Adjust assy
QTY
1
1734 O-ring
QTY
1
13.94mm x 2.62mm
0.549in x 0.103in
1734 O-ring 13.94mm x 2.62mm
0.549in x 0.103in
QTY
2
1959 O-ring 9.25mm x 1.78mm
0.364in x 0.070in
QTY
2
3129 O-ring 6.07mm x 1.78mm
0.239in x 0.070in
QTY
1
3130 O-ring 21.94mm x 1.78mm
0.864in x 0.070in
QTY
2
3150 Backup ring
3131 O-ring 21.82mm x 3.53mm
0.859in x 0.139in
QTY
1
3132 O-ring 15.54mm x 2.62mm
0.612in x 0.103in
QTY
1
3303 O-ring 34.92mm x 1.78mm
1.375in x 0.070in
QTY
1
3151 Backup ring
QTY
1
3152 Rod Seal
QTY
1
3176 Allen key, 3mm
QTY
1
3177 Allen key, 4mm
QTY
1
3178 Allen key, 5mm
QTY
1
QTY
1
Note: The full-size o-ring diagrams
may not reproduce to scale when
printed from the pdf download.

GaugeCalXP Service Instruction Sheet • Page 7
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How to Contact Us:
Phone [phone]
Toll-Free [phone]
Fax [phone]
Email [e-mail]
Web www.crystalengineering.net
Send your comments to: f[email protected]
Routine Flushing
If a complete rebuild is not required, flushing 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
flush should always be performed by a qualified technician.
Flushing Instructions
1 Remove all gauges or stem adapters from both the flange stem and gauge base.
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 end block) and lift to tip the GaugeCalXP on its
end. Any hydraulic fluid in the system will run out through the rear Gauge Base port.
4 Set the unit back down, flat on the Baseplate, and begin to pour isopropyl alcohol, warm soapy
water, or clean hydraulic oil into the reservoir. Continue to fill the unit until the fluid begins to
run out of the Gauge Base ports. Always dispose of fluids in a responsible manner.
5 Once again, tip the GaugeCalXP on its end until all of the fluid in the system has drained out.
6 Set the unit back down, then wind the handle clockwise at least 10 turns, then fill the reservoir
with test fluid to within 6mm (1/4") from the top.
7 Follow the operator instructions supplied with your GaugeCalXP to fill the system and begin
calibration testing.
CAUTION: Solvents can damage o-rings and should never be used when flushing or otherwise
cleaning the GaugeCalXP.
3133 Fine Adjust assy
QTY
1
1734 O-ring
QTY
1
13.94mm x 2.62mm
0.549in x 0.103in
1734 O-ring 13.94mm x 2.62mm
0.549in x 0.103in
QTY
2
1959 O-ring 9.25mm x 1.78mm
0.364in x 0.070in
QTY
2
3129 O-ring 6.07mm x 1.78mm
0.239in x 0.070in
QTY
1
3130 O-ring 21.94mm x 1.78mm
0.864in x 0.070in
QTY
2
3150 Backup ring
3131 O-ring 21.82mm x 3.53mm
0.859in x 0.139in
QTY
1
3132 O-ring 15.54mm x 2.62mm
0.612in x 0.103in
QTY
1
3303 O-ring 34.92mm x 1.78mm
1.375in x 0.070in
QTY
1
3151 Backup ring
QTY
1
3152 Rod Seal
QTY
1
3176 Allen key, 3mm
QTY
1
3177 Allen key, 4mm
QTY
1
3178 Allen key, 5mm
QTY
1
QTY
1

CRYSTAL
engineering corporation
© 2005 Crystal Engineering Corporation
708 Fiero Lane, Suite 9, San Luis Obispo, California 93401-8701
PN: 3175—Rev A