KJ1000 Operating Instructions & Parts Manual
Contents
1. 9889 POTIAS ISIMIIYJO sso u 31720190139 22117947 SHTONV XX XXX Pl 01704 sn PUEW jeun wd SHHONI NI TAY SNOISNHIAIG Spuooos G SNUIW 10 Sn d spuooos 8 10J 8191 JJO 39S Spuooos G SNUIU 10 sn d spuooos QI 70 48191 uo oui 39S ii SION GddV ALVA NOLLdISIOSHG AR SNOISIAHA M KA SSald IH ssadq 407 sectes to AR LMD Ore J JOJA 9314497 BA E A e 9 E S z Alddns uod 0A Th z 37515758178 E D HAEN HA LA 4 OL LD di v OF a dH 5 7 Page 11 KJ1000 Nitrogen Intensifier OPTIONAL PRODUCTS LIST Product Number Product Description KJ1045 System Cart 5 High KJ1046 oystem Cart 32 High KJ1041 Gage Set KJ1042 Crossover Line KJ1043 Nitrogen Discharge Hose KJ1044 Tank Fill Stem 3000 PSI KJ1044B Tank Fill Stem 5500 PSI KJ1047 Tank Regulator Set KJ1048 Nitrogen Extraction Kit See next page for photos and product descriptions WHEAT EMIS i To Order Call 1 888 922 8502 Mandus Group Ltd 2408 4th Avenue Rock Island IL 61201 1 888 922 8502 ae www mandusgroup com Page 12 KJ1047 Tank Regulator Set For use with 2000 PSI nitrogen tanks Delivery range KJ1046 32 Cart For use O to 2500 PSI Comes with 15 with the KJ4000 Oil ft discharge hose to couple up Transfer System or KJ1000 With KJ1000 Nitrogen Intensifier KJ1045 5 Cart For use with the KJ4000 Oil Transfer System or KJ1002. DO NOT attempt to use the KJ1000 and its accessories in any way other than their intended use NEVER USE any oil in the KJ1000 other than the specified oil GENERAL MAINTENANCE INFORMATION Inspect all oil lines and connections twice a year for any cracks leaks or excessive wear Inspect electric cord once a year for any excessive wear cracks or exposed wires Change oil every 2 years Change Nitrogen Extraction filter yearly Inspect heat exchanger cooling fins once yearly for damage and dirt Clean with air hose if necessary If a blowing oil mist is ever present when disconnecting Schrader Valves at equilibrators or at the recuperator the following steps may need to be taken Step 1 Replace gas filter element in the Nitrogen Extraction Kit and determine if blowing oil mist stops If it does not perform step 2 Step 2 Contact Mandus Group Ltd for accumulator bladder replacement Page 1 MANDUS GROUP 888 922 8502 SAFETY INSTRUCTIONS SUMMARY The following are general safety precautions that are not related to any specific procedures and therefore do not appear else where in this manual These are general safety precautions that operators and maintenance personnel must understand and apply during many phases of operation and maintenance to ensure personal safety and protection of the equipment Throughout this manual three types of notations are provided which contain special information NOTE Provide
3. Close the Schrader valve on the equilibrators or recuperator and also turn off the receiving tank valve Slowly bleed off nitrogen pressure within the KJ1000 and lines by cracking the bleed valve on the discharge hose refer to Page 5 Item 9 Make sure the pressure gage on the KJ1000 reads 0 zero PSI before disconnecting lines Note Mandus Group Ltd recommends that the customer replace the nitrogen filter element annually Contact Mandus Group Ltd for ordering information Page 9 Trouble Shooting the KJ1000 Problem 1 KJ1000 won t turn on 2 KJ1000 won t fill vessel 3 Oil mist present when disconnecting Schrader Valve OR D O OSI O O1 R ND Possible Solution Circuit breaker off in control panel Not plugged in Supply pressure not open Supply pressure less than 150 PSI Destination pressure is above 1950 PSI Kink in inlet line Obstruction in inlet line Kink in outlet line Needle valves not removed Schrader valve is bad Low oil in reservoir Drop cord is over 50 ft long Drop cord is not 12 AWG Supply pressure is below 200 PSI otep 1 Replace gas filter element in the Nitrogen Extraction filter and determine oil mist stops If it does not perform step 2 Step 2 Contact Mandus Group Ltd for accumulator bladder replacement Page 10 1010001 CM 99 AIAT 58900 uly TOPA quiossy 1XON penou ou SMC 90 9
4. 0 Nitrogen Intensifier KJ1041 Gage Set For checking and bleeding nitrogen pressure in equilibrators and recuperators on the 198 Howitzer KJ1043 Nitrogen Discharge Hose For use with the KJ1000 Nitrogen Intensifier and KJ1042 Crossover Line or to be used with the KJ1000 Nitrogen Intensifier and the KJ1044 Tank Fill Stem KJ1044B Tank Fill Stem For use with KJ1044 Tank Fill Stem For use with the KJ1000 the KJ1000 Nitrogen Intensifier and the Nitrogen Intensifier and the KJ1043 Nitrogen KJ1043 Nitrogen Discharge Hose The Discharge Hose The tank fill stem allows tank fill stem allows consolidation of low consolidation of low pressure nitrogen bottles into pressure nitrogen bottles into one tank at one tank at pressures from 0 to 3000 PSI pressures from 0 to 5500 PSI KJ1042 Crossover Line To be used with the KJ1000 Nitrogen Intensifier to fill equilibrators on a 198 Howitzer Can couple up with the standard discharge hose on the KJ1000 or the KJ1043 Nitrogen Discharge Hose Page 13 KJ4000 Oil Transfer System NSN 1025 01 473 7710 The KJ4000 Oil Transfer System is a newly developed technology for use as an alternative to the M3 oil pump currently being used by all branches of the Armed Services The KJ4000 provides 59 GPM of oil flow for ease in filling oil reservoirs as well as recoil mechanisms buffers and replenishers The KJ4000 can provide oil pressure up to 2500 PSI The KJ4000 is
5. 1 Page 7 Reclaiming Operation Illustration KJ1000 NITROGEN INTEN SIFIER SCHRADER GAS CHUCK RECEIVING TANK PRESSURE GAGE ol START STOP KJ1044 or KJT044B Use this line item 4 page 5j and this adaptor item 11 page 5j ta connect ta the M198 Howitzer Use this line Litem 8 page 5 to fill a tank 11 RECUPERATOR EQUILIBRATOR RECEIVING TANK Page 8 NOTE Remove needle valve from the valve stem if one is present in the equilibrator crossover line This allows a more efficient transfer process 5 B ves Attach the gas chuck end of the discharge hose with the adapter to the valve on the crossover line or to the Schrader valve on the recuperator equilibrator Plug the KJ1000 in to your electrical source Slowly open the tank valve on the receiving tank until it is fully open Slowly open the Schrader valve or valves at the equilibrator or the recuperator until fully open When the nitrogen supply and source vessel pressures have equalized turn on the KJ1000 Run the KJ1000 for approximately 20 minutes and then turn it off Unless it turns off automatically The KJ1000 is designed to turn off when supply pressure drops below 150 psi After 20 minutes you will have reclaimed all but 150 psi of the nitrogen in your supply vessel IMPORTANT You still have residual pressure in the equilibrator set or recuperator This pressure must be bled off if maintenance is to be performed 11
6. IONS amp PARTS MANUAL Model KJ1000 Please read and save these instructions Read carefully before attempting to assemble install operate or maintain the product described Protect yourself and others by observing all safety information Failure to comply with instructions could result in personal injury and or property damage Retain instructions for future reference Mandus Group Description The KJ1000 Nitrogen Intensifier was developed to assist in filling nitrogen vessels The KJ1000 is designed to utilize and intensify all but 150 PSI of nitrogen from the supply bottle The KJ1000 accepts nitrogen from a supply source then intensifies the nitrogen source pressure by means of a hydraulic pump and electric motor The intensified nitrogen is then forced into an accepting nitrogen vessel The KJ1000 is engineered to shut down when 150 PSI or less is left in the supply bottle or when the factory set upper level pressure 1950PSI is obtained Unpacking KJ1000 When unpacking the KJ1000 inspect for any loose missing or damaged parts Notify Mandus Group Ltd as soon as possible if there are missing or damaged parts KJ1000 uses ISO100 anti leak anti wear anti foam or equivalent hydraulic oil Unit is shipped with oil General Safety Information 1 Do not use any gas but nitrogen in the KJ1000 2 Do not operate KJ1000 on less than a 20 amp service WARNING Do not exceed the maximum input or output pressure of 2500 psi o
7. KJ1000 Operating Instructions amp Parts Manual NSN 1025 01 473 8886 Mandus Group Ltd KJ1000 Operators Manual TABLE OF CONTENTS General Safety Instructions cccccsseeecceeeeceeeeconsescesecceseeseneesceeescees Page 1 2 Operator Instructions Page 3 4 KJ1000 Repair Parts LAS I T T TM Page 5 KJ1000 Repair Parts List Description eesseeeseeeees sss Page 6 Nitrogen Reclaiming Instructions mnrnnrenenennenne nunnana Page 7 8 9 Trouble Shooting Procedures eese Page 10 Electrical Schematic enna Page 11 KJ1000 Optional Products LISE essor certo ika Sk annin Page 12 13 KJ 900 Information Data nnn Page 14 KJ4000 Optional Products List Page 15 Warranty Nior malol aata a maana e DAR e Page 16 Mandus Group GENERAL SAFETY INFORMATION DO NOT operate the KJ1000 or any of its components without first reading and understanding all the operating instructions first DO NOT operate the KJ1000 unless the oil level in the reservoir is 1 2 inch from the top of the reservoir DO NOT operate the KJ1000 at temperatures greater than 110 degrees F or less than 5 degrees F DO NOT operate the KJ1000 on less than a 20 amp service DO NOT attempt to apply more than 2500 psi anywhere to the KJ1000 DO NOT attempt to lift the KJ1000 with less than two men The KJ1000 weighs approx 175 Ibs
8. e marked for other gasses Always check the cylinder markings and ensure that only cylinders marked for nitrogen are charged with nitrogen Do not use adapters to fill cylinders that do not have the correct fittings for nitrogen WARNINGS e Improper use of this product may cause severe personal injury of death Read and understand this manual before using or servicing this product e Make sure any equipment connected to the KJ1000 is rated for the applicable pneumatic pressure e Only factory supplied assemblies may be interchanged to repair the KJ1000 Interchange of parts or assemblies between KJ1000 units may result in damaged parts or components and could void warranty CAUTIONS e Risk of electrical shock DO NOT remove covers Refer servicing to qualified service personnel e Hose fittings must be leak tight A small leak can severely impair performance of the KJ1000 e If an extension cord must be used to deliver power to the KJ1000 ensure that it is adequately sized and in good repair e Risk of electrical shock Refer servicing to qualified service personnel Page 2 Operation Illustration RECEIVING TANK Fegulator and Line ul supplied by Customer 85 E START STOP KJ1044 or 14110448 Pi Male quick disconnect supplied by Mandus Group You can use this discharge item 6 page 5 line to fill a tank or use the other one item 8 page 5 directly on the weapon RECEIVING TANK Page 3 OPERATING INSTRUCT
9. engineered to self purge its system and lines of air prior to pumping oil The KJ4000 accepts oils from pressurized systems through the same line it discharges from by means of an innovative design This design allows oil to flow through a 5 micron high pressure filter in either direction whether it is from a pressurized system or to a pressurized system or reservoir Available Options An alternative to the M3 oil pump 5 gallon reservoir with sight glass Increases productivity standard option 59 GPM of flow Self purging design to eliminate pumping Manual hand pump back up 7 cubic air into a closed system inches per cycle Quick disconnects on all fittings and hoses 5 micron filter for transferring fluids to and 15 foot oil transfer hose standard option from pressurized system Eliminates need for waste oil disposal Indicator gage for alerting user when 5 Size 20 W X21 DX 22 1 2 H micron filter change is required Weight 145 Ibs Year Warranty 8 gallon reservoir 25 foot power supply cord 20 and 25 foot oil transfer hose Digital totalizing meter Mandus Group Mandus Group Ltd 2408 4th Avenue Toll Free 888 922 8502 Rock Island IL 61201 www mandusgroup com MV Page 14 Product Number KJ1045 KJ1046 KJ4041 KJ4042 KJ4043 KJ4044 KJ4042 Reservoir Fill Line For use with the KJ4000 Quick couples with the pump for easy loading of oil to reservoir from a ca
10. le quick disconnect on it to connect to the female quick disconnect on the KJ1000 YOU CANNOT USE A REGULATER ON THE RECEIVING TANK You must use the KJ1044 or KJ1044B There should be a 15 foot discharge hose with female disconnects on both ends This hose comes standard with the unit One end attaches to the KJ1000 and the other end attaches to the receiving tank via the KJ1044 or 1044B the KJ1044 CGA 580 is for tanks up to 3000 psi the KJ1044B CGA 680 is for tanks from 3000 psi up to 5500 psi Once you have both tanks Source tank and Receiving tank connected to the KJ1000 Turn the valves on both tanks slowly open until they are wide open The pressure gage on top of the KJ1000 illustrates the pressure in the receiving tank Plug the KJ1000 in and press the start button on the hand pendant The unit should start to run and will continue running until the receiving tank reaches approximately 1850 psi or until you shut machine off Page 4 KJ1000 Parts List Mandus Group N Page 5 Ref Number O OSI 0 1 R ND Mandus Group Nu Part Number KJ1000FA KJ1000PU KJ1000EX KJ1000MA KJ1000EK KJ1000AA KJ1000EA KJ1000H1 KJ1000H2 400077LW KJ1000A1 9928070 9928020 KJ1044 KJ1044B KJ1000FE Page 6 Repair Parts List Description Frame Assembly Power Unit Assembly Heat Exchanger Assembly Manifold Assembly Extraction Kit Assembly Accumulator Assembly Electrical Assembly Hose Assembl
11. n barrel or bucket KJ1046 32 Cart For use with the KJ4000 Oil Transfer System or KJ1000 Nitrogen Intensifier KJ4000 Oil Transfer System OPTIONAL PRODUCTS LIST Product Description System Cart 5 High System Cart 32 High Oil Releasing Tool Reservoir Fill Line Recirculation Kit Flow Meter amp Gage Kit 27 KJ4041 Oil Releasing Tool For use with the KJ4000 Oil Transfer System to fill or drain the recuperator on the 198 Howitzer Made of stain less steel KJ4043 Recirculation Kit For use with the KJ4000 Used to recirculate oil through the recoil mecha nism of a variety of weapon systems KJ1045 5 Cart For use with the KJ4000 Oil Transfer System or KJ1000 Nitrogen Intensifier KJ4044 Flow Meter amp Gage Kit For use with the KJ4000 Oil Transfer System to determine how much oil is flowing through the KJ4000 and into the receiving sys tem The gage will determine how much pressure is in the system while transferring oil MandusGroup To Order Call 1 888 922 8502 Mandus Group Ltd EGGS EEE Page 15 2408 4th Avenue Rock Island IL 61201 1 888 922 8502 www mandusgroup com Mandus Group Ltd Manufacturer s Limited Warranty For one year from date of purchase Mandus Group Ltd will repair or replace at its expense and at its option any KJ4000 machine part or machine accessory which in normal use has proven to be defective in workmanshi
12. p or material provided that the customer returns the product prepaid to Mandus Group Ltd s repair service center and provides Mandus Group Ltd with reasonable opportunity to verify the defects by inspection Mandus Group Ltd will not be responsible for any asserted defect which has resulted from normal wear misuse abuse or repair or alteration made or specifically authorized by anyone other than an authorized Mandus Group Ltd service facility or representative Under no circumstances will Mandus Group Ltd be liable for incidental or consequential damages resulting from defective products This warranty is Mandus Group s sole warranty and sets forth the customer exclusive remedy with respect to defective products All other warranties expressed or implied whether of merchantability fitness of purpose or otherwise are expressly disclaimed by Mandus Group Ltd Page 16
13. r operate at temperatures lower than 5 degrees F or higher than 110 degrees F WARNING Never attempt to uncouple the quick connects anywhere on system while it is under pressure Set up 1 Remove air chuck and coupling from the customer owned nitrogen charging kit and install the male quick connect provided with the KJ1000 to the end of the hose NOTE Remove needle valve from the valve stem if one is present in the equilibrator crossover line This allows a more efficient transfer process NOTE Do not use a drop cord of more than 50 feet in length and wire gage of cord should be rated at 12 awg Failure to follow this information could result in damage to the KJ1000 KJ1000 Nitrogen Intensifier Mandus Group Ltd 2408 4th Avenue Hock Island IL 61201 1 888 922 8502 www mandusgroup com Operating Instructions The KJ1000 requires to be hooked up to a source tank with at least 150 psi refer to illustration on page 3 The KJ1000 has a pressure switch in it that won t allow operation unless it has a minimum of 150 psi on the inlet line There are 2 connection fittings on the KJ1000 They are right next to each other and are clearly marked on the cover as INLET and OUTLET The female quick disconnect is the inlet connection on the manifold The male quick disconnect on the manifold is the outlet Your source tank should have a regulator on it with a gas line coming off of it The end of this line must have a ma
14. s additional information that may be helpful in performing a specific task CAUTION Provides information about conditions which require special attention and precautions to avoid serious or fatal injuries WARNING Provides information about conditions which require special attention and precautions to avoid serious or fatal injuries GUIDELINES FOR HANDLING COMPRESSED GAS CYLINDERS Nitrogen cylinders are under extremely high pressure up to 2500psi and present a number of associated hazards as a result The sudden release of the cylinder pressure whether by puncture damage to a valve caused by dropping or other means can turn the cylinder into a missile which can travel along the ground or through the air at high speeds Take extreme care when filling and handling charged cylinders Do not drag or slide the cylinders by the pressure cap this may cause the sudden release of cylinder pressure Use a suitable hand truck fork lift or similar device for handling large cylinders Do not drop cylinders or permit them to strike against each other or other surfaces this may cause the sudden release of pressure Securely secure the cylinders during filling storage and transport Do not fill cylinders too rapidly excessive heat may build up in the gas which could result in a failure of the cylinder valve seals and possible fire Periodically check the surface temperature of the cylinders during charging Never charge cylinders with nitrogen that ar
15. y 1 Hose Assembly 2 25 Ft Drop Cord Adapter Assembly Female Disconnect Male Disconnect Tank Fill Stem 3000 PSI Tank Fill Stem 5500 PSI Filter Element Mandus Group N INSTRUCTIONS FOR RECLAIMING NITROGEN FROM AN M198 HOWITZER 1 Tank Fill Stem Assembly KJ1044 or KJ 1044B Item 14 and 15 Page 5 should be attached to a standard nitrogen tank with a CGA580 or CGA680 valve respectively that you are transferring nitrogen TO NOTE When this destination tank reaches approximately 1950 PSI the KJ1000 will shut down You must then connect Tank Fill Stem to another available tank with less than 1950 PSI NOTE It is assumed that the operator of this equipment is already familiar with the KJ1000 and its operation Make sure you have read the KJ1000 operating instructions and thoroughly understand them Failure to do this could cause serious injury 2 Install the adapter Item 11 Page 5 into the female quick connect end of the discharge hose see figure A Use discharge hose with Schrader gas chuck attached see Page 5 Item 9 Figure A 3 Now install the adapter end of the discharge hose from step 2 into the inlet side of the KJ1000 refer to Page 4 Attach one end of the second discharge hose female disconnect on each end refer to Page 5 Item 8 to the male quick connect on the KJ1000 Page 8 Attach the other end of this hose to the Tank Stem Kit that you attached to the receiving tank in step
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