Dover Hydro Xtreme User manual

service guide

Hydro Xtreme Diaphragm Pump

To properly maintain your Hydro Xtreme diaphragm pump, you must service it after every 10,000 hours of operation. Hydro

Systems offers a comprehensive service kit with which you can refurbish your Hydro Xtreme pump. NOTE! The HYD710 style

pump and parts kit are used as the examples in this procedure, but if you have a chlorine dioxide pump the steps to perform

are the same even if the appearance of the pump and service parts are slightly different.

Step 1: Rinse pump and tubes with clean water

Run clean water through your unit in order to remove any

residual chemical that exists in the pump lines.

Step 2: Unplug pump and turn off water supply

Unplug the power cord of your Hydro Xtreme pump, and turn

off the water flow into which the chemical is being injected.

Safety Precautions

WARNING! Please read precautions thoroughly before operation. Meet all applicable local codes and regulations.

Thank you for purchasing Hydro Systems’ products!

Please use this equipment carefully and observe all warnings and cautions.

protective clothing and eyewear when dispensing chemicals or other materials or when working in the

vicinity of all chemicals, filling or emptying equipment, or changing metering tips.

observe safety and handling instructions of the chemical manufacturer.

direct discharge away from you or other persons or into approved containers.

dispense cleaners and chemicals in accordance with manufacturer’s instructions.

exercise CAUTION when maintaining your equipment.

reassemble equipment according to instruction procedures. Be sure all components are firmly screwed or

latched into position.

equipment clean to maintain proper operation.

WEAR

ALWAYS

KEEP

Safety First! Before you start any maintenance to the pump, make sure that you follow the necessary safety precau-

tions listed above and as outlined in the Hydro Xtreme Quick Start Guide that came with the pump.

Step 1:

Rinse

Pump

and

Tubes

Step 2:

Unplug

Pump,

Turn off

Water

Hydro

Xtreme

HYD710

Style: For

Hydrogen

Peroxide

& Sodium

Hyper-

chlorate HYD10098984 - Hydro Xtreme Service Kit, HYD710 style

Hydro

Xtreme

HYD712

Style: For

Chlorine

Dioxide

HYD10098997 - Hydro Xtreme Service Kit, HYD712 style

Step 3: Release Pressure with Relief Valve

Release any pressure that may have been built up in the pump

head, by rotating the relief valve clockwise by ninety degrees

or 1/4 turn.

Step 4: Remove Intake and Discharge Lines

Remove the intake hose from the chemical pickup (suction)

side of the pump, but unscrew the discharge line from the

injection fitting on the water line.

Step 5: Remove Diaphragm Assembly

a) Remove the four screws that hold the pump head to the

pump body. You must loosen the screws a little at a time

in an “X” pattern, like upper left, lower right, lower left then

upper right.

b) Once the screws are removed, take off the pump head,

and then the outer O-ring.

c) Now you can remove the diaphragm assembly components.

• the diaphragm

• the auxiliary ring

• the protective diaphragm

Rotate the diaphragm counter-clockwise to remove.

d) Carefully pull off the auxiliary ring, and set aside for

reassembly

e) Finally, you can remove the protective diaphragm. Take care

of the diaphragm, as it will be reused during assembly.

(The auxiliary ring and protective diaphragm are

both shown in the image to the right.)

Clean and inspect both parts before trying to rebuild the

pump, as these components are reused for assembly.

Step 3:

Release

Pressure

w/Relief

Valve

Step 4:

Remove

Intake &

Discharge

Lines

Step 5a:

Remove

Head

Screws

Loosen

Screws

in “X”

Pattern

Step 5b:

Remove

Pump

Head &

O-ring

Step 5d:

Remove

Auxiliary

Ring

Take care of these items, as

they are reused for assembly!

Step 5c:

Remove

Diaphragm

Step 5e:

Remove

Protective

Diaphragm

Protective

Diaphragm

Auxiliary

Ring

Step 6: Rebuild Diaphragm Assembly

a) To rebuild the diaphragm assembly, start by reinstalling

the original protective diaphragm, followed by the original

auxiliary ring.

(Note! The auxiliary ring is keyed. Please make sure it lines

up accordingly.)

b) Install the new diaphragm by screwing it in clockwise until it

is hand tight.

c) Once the diaphragm is secure, install the new outer O-ring

into its channel.

d) Finally, you can reinstall the pump head to the pump body.

Tighten the four screws a little at a time in an “X” pattern,

like upper left, lower right, lower left then upper right.

Step 6d:

Reinstall

Pump

Head

Tighten

Screws

in “X”

Pattern

Step 6c:

Install

New

Outer

O-ring

Step 6b:

Install

New

Diaphragm

Step 6a:

Reinstall

Protective

Diaphragm

and

Auxiliary

Ring

Step 7: Rebuild Pump Discharge Fitting

The discharge fitting on your Hydro Xtreme pump is at the top.

a) Start by loosening the compression nut (counter-clockwise),

with a 1 1/8” (290 mm) wrench or an adjustable wrench.

When loosened, unscrew the nut completely and set the

nut, the retaining ring and discharge tube aside.

b) Unscrew the rest of the discharge fitting from the pump

body, using the same size wrench. Remove it from the

pump and slide the O-ring, check valve(s) and spacer from

inside. Take care of the spacer, as it may have to be reused.

c) Replace the spacer, check valve(s) and O-ring with new

parts, and reassemble them into the discharge fitting.

NOTE: The black ring end of a check valve always faces the

flow, so here they are always towards the bottom.

NOTE: The new spacer should be the same size as the old

one. If not, re-use the old spacer and please notify Hydro

Systems of the discrepancy.

Step 7a:

Remove

Compres-

sion Nut,

Retaining

Ring and

Tubing

Step 7b:

Remove

Discharge

Fitting

Step 7c:

Rebuild

Discharge

Fitting with

New Parts This check-valve orientation is correct

only for the upper (discharge) fitting

Hydro Systems

3798 Round Bottom Road

Cincinnati, OH 45244

Phone 513.271.88OO

Toll Free 8OO.543.7184

Fax 513.271.O16O

Web hydrosystemsco.com

HYD10099324 Rev A 6/19

Limited Warranty

Seller warrants solely to Buyer the Products will be free from defects in material and workmanship under normal use and

service for a period of one year from the date of completion of manufacture. This limited warranty does not apply to (a) hoses;

(b) and products that have a normal life shorter than one year; or (c) failure in performance or damage caused by chemicals,

abrasive materials, corrosion, lightning, improper voltage supply, physical abuse, mishandling or misapplication. In the event

the Products are altered or repaired by Buyer without Seller’s prior written approval, all warranties will be void.

No other warranty, oral, express or implied, including any warranty of merchantability or fitness for any particular

purpose, is made for these products, and all other warranties are hereby expressly excluded.

Seller’s sole obligation under this warranty will be, at Seller’s option, to repair or replace F.O.B. Seller’s facility in Cincinnati,

Ohio any Products found to be other than as warranted.

Limitation of Liability

Seller’s warranty obligations and Buyer’s remedies are solely and exclusively as stated herein. Seller shall have no other

liability, direct or indirect, of any kind, including liability for special, incidental, or consequential damages or for any other claims

for damage or loss resulting from any cause whatsoever, whether based on negligence, strict liability, breach of contract or

breach of warranty.

warranty

Step 7: Rebuild Pump Discharge Fitting (continued)

d) Reassemble the (upper) discharge fitting, following the steps

of this section in reverse.

Be careful not to over-tighten the plastic fitting to the pump,

nor the compression nut.

Step 8: Rebuild Pump Intake Fitting

The steps to service the (lower) intake fitting are the same as

for the (upper) discharge fitting.

However, remember that the black ring end of the check-

valve(s) must be facing the flow, in this case that means always

toward the bottom.

Step 7d:

Finish

Rebuilding

Discharge

Fitting

Step 8:

Rebuild

Intake

Fitting as

you did the

Discharge

Fitting

This check-valve orientation is correct

only for the lower (intake) fitting

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