KAYOBA 016592 PCP Hand Pump Instruction Manual

Item no. 016592

PCP HAND PUMP
OPERATING INSTRUCTIONS Important! Read the user instructions carefully before use. Save them for future reference. (Translation of the original instructions).
Jula reserves the right to make changes. For latest version of operating instructions, see www.jula.com

1

SYMBOLS

****| Read the instructions.
| Approved in accordance with the relevant directives.
| Recycle discarded products in accordance with local regulations.

TECHNICAL DATA

DESCRIPTION

1. Handle
2. Inlet valve
3. Ball seal, an inlet valve
4. Ring seal, an inlet valve
5. Guide pin, tertiary stage
6. Primary stage tube (broadband)
7. External seals, primary stage piston
8. Primary stage
9. Piston seals, primary stage piston
10. Pressure gauge
11. Folding base
12. Air hose
13. Secondary stage tube (medium)
14. Guide, tertiary stage
15. Ring seal, tertiary stage
16. Piston, secondary stage
17. Top, tertiary stage tube seal
18. Top tube ring seal, tertiary stage
19. Top duct ring seal, tertiary stage
20. Piston seals, secondary stage tube
21. Piston seals, secondary stage tube
22. Tertiary stage tube (high-pressure tube)
23. Ring seal, tertiary stage tube
24. Ring seal, tertiary stage tube
25. Bottom, tertiary stage tube seal
26. Damper ring
27. High-pressure valves, the primary stage
28. High pressure valves
29. Spring
30. Top cover
31. Ring seal
32. Piston rod, tertiary stage
33. Piston, tertiary stage
34. Piston guide ring
35. Piston ring
36. Piston guide ring
37. Lock ring

**FIG. 1**

INSTALLATION

1. Fit gasket.
2. Check 0-ring.
3. Fit primary stage tube.
4. Tighten tube.
5. Fit hose.
6. Fit pressure gauge.
7. Tighten pressure gauge with a spanner.
8. Fit handle.
9. Tighten screw.

FIG. 2

TESTING

1. Connect test connector to male quick-coupling 8 mm, open venting valve and pump 20 times. if the product is working properly it should be easy to pull up and press down the handle by applying about 2.4 kg.
2. Close the venting valve and open it again when the pressure reaches 100 bar to relieve the pressure.
3. Close the venting valve, pump up to 200 bar and wait 2 minutes. Check that the pressure shown on the pressure gauge does not drop (which would indicate leakage). To check for leakage put the pump base in water, together with the inlet hose and test connector.

USE

1. Make sure the hose is not bent or tangled.
2. Conned the pump to the equipment with original parts.
3. Close the venting valve.
4. Stabilise the product with foot on the base.
5. Move the handle up and down to pump. When the pressure exceeds 100 bar the pumping is stiffer. This is perfectly normal. After pumping, open the venting valve to release residual air in the pump and hose. A little fluid can come out, this is perfectly normal.

WARNING!
Do not release the connections before the pressure is relieved.

MAINTENANCE

1. Lubricate the product after 800 cycles. Apply 3 drops of silicone oil on the top handle and a few drops in the second stage tube.
2. Check that the female connector is correctly mounted, otherwise, there is a risk of seizure. The dimension of the quick-coupling is 8 mm.
3. Relieve the pressure in the product when not in use. Do not bend or fold the hose, or knock the pressure gauge.
4. The cooling water is contained between the secondary and tertiary tubes. No refilling is necessary. The water cooling works through the transfer of heat. It is normal for the product to feel hot when in use.

TROUBLESHOOTING

The pressure does not increase or increase slowly, even though the product is correctly connected.| Leakage.| Put the hose in the water and pump to see where air leaks out.
The pump handle is stiff and sinks automatically after it is pulled up.| The non-return valve in the three-stage piston is not working.| Open the venting valve on the primary stage tube and drip a small amount of silicone oil into the tube. Close the valve and pump rapidly a few times to remove the blockage.
Open the three-stage piston to localize the leakage, or replace the piston seal.
It is easy to pull up the pump handle, but difficult to press it down, or it moves up automatically.| The bottom non-return valve is defective, blocked, or leaking.| Remove the bottom non-return valve with a spanner and clean or replace it.
It is more and more difficult to pump, both up and down.| Inadequate lubrication.| Apply silicone oil.

NOTE: Pump a few strokes after applying silicone oil to press out any residual oil.
Excess silicone oil can cause an explosion.

The pressure gauge is not reset.| If there is excess oil in the product the oil and gas will expand when the pressure reaches 200 bar. The pressure will then quickly increase to 400 bar, which exceeds the maximum permitted pressure for the pressure gauge and will damage it. The pressure gauge can also have been subjected to knocking.| Replace the pressure gauge.

JULA AB, BOX 363, SE-532 24 SKARA
2022-03-14
© Jula AB

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| KAYOBA 016592 PCP Hand Pump [pdf] Instruction Manual
016592, 016592 PCP Hand Pump, PCP Hand Pump
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