Universal Pump Service Manual
7
7
7
7
7
Pump Disassembly
Tools
• Universal XR Series pump
• Needle nose pliers
•
Dual-ball rotameter,
valve,
• Phillips head screwdriver
• Small fl at-head screwdriver
magnehelic gauge connected with
• Small Allen wrench
• Water manometer
tubing in line and in order
• Pliers
• Pump exhaust port fi tting
• Large syringe
Removing the Battery Pack
1. Turn the pump over so that the belt clip is facing upward.
2. Using a Phillips head screwdriver, remove the two right-hand screws (Figure 3, #5).
3. Slide the ba ery straight out to the right.
Lifting up while disconnecting the battery pack can damage the battery pins.
Removing the Back of the Pump Case
1. Using a Phillips head screwdriver, loosen and remove the four screws on the back of the pump case (Figure 3, #7).
2. Holding the fi lter housing assembly fi rmly, li" the back half of the case (with belt clip) off the front half.
Locating and Correcting Leaks
If the pump failed functional testing, it could be due to a leak. Locate and correct the leak(s). The ba ery pack, back pump
case, and stack must be removed from the front pump case to perform the following steps (see Pump Disassembly, Removing
the Ba ery Pack, Removing the Back of the Pump Case, and Disassembling the Stack, Steps 1 through 3).
Filter Housing and Flowmeter Assemblies Leak Check
1. Remove the fi lter housing (Figure 2, #3) and fl owmeter assemblies from the stack (Figure 2, #4).
See Pump
Disassembly, Disassembling the Stack, Steps 1 through 3.
2. A ach the fi lter housing inlet to a water manometer (Figure 6).
3. Place a fi nger over the short black tubing on the fl owmeter.
4. Apply pressure and observe the water column. If it moves, pinch the long black rubber tubing that connects the
fi lter housing assembly to the fl owmeter assembly.
5. Apply pressure and observe the water column.
If the water column remains steady, the leak is in the fl owmeter. If the column moves during this test, there is a leak in
the fi lter housing assembly. Replace fi lter housing or fl owmeter as indicated by this test and repeat Steps 2 through 5.
Regulator and Pulsation Dampener Assemblies Leak Check
1. Remove the regulator assembly (Figure 2, #1) and the two pulsation dampener assemblies (Figure 2, #2) from the
stack by loosening the screw beside the pump exhaust port and the screw beside the regulator isolation valve
(Figure 2, #11). (
See Pump Disassembly, Disassembling the Stack, Step 4.)
Ensure there is an O-ring seated at the bottom of the exhaust port. If it is missing, replace it to prevent
the port from leaking.
2. A ach the stack (regulator) inlet (Figure 2, #14) to a water manometer (Figure 6).
3. Cover the inlet passage on the bo om of the top half stack (Figure 2, #15) with a fi nger.
4. Holding the assembly fi rmly, apply not more than 20 inches of pressure and observe the water column. If there is
movement, there is a leak in one of the assemblies.
5. Remove the bo om pulsation dampener assembly (Figure 2, #2) and repeat Steps 3 and 4. If there is no movement,
replace the bo om pulsation dampener with a new one and you have fi xed the leak. If there is still movement in
the water column, see Step 6.
