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Summary of Contents for Mandus Group KJ4000CV
- Page 1 Operating Instructions & Parts Manual Oil Transfer System KJ4000CV NSN: 4933-01-572-0092 December 13, 2022 1st Edition, Rev. 0 Chg. 1 © Mandus Group Mandus Group LLC Phone: 1-888-922-8502 2408 4th Avenue E-Mail: customerservice@mandusgroup.com Rock Island, IL 61201 Website: www.mandusgroup.com...
- Page 2 KJ4000CV This information is believed to be accurate by the Mandus Group as of its date of publication, but the Mandus Group offers NO WARRANTY regarding the accuracy, or continuing accuracy, of the information set forth herein. The Mandus Group shall not be liable for inaccuracies in, or consequences resulting from, your use of this information.
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Page 3: Table Of Contents
INSTRUCTIONS FOR USING THE KJ4044 – FLOWMETER AND GAUGE KIT ........15 Troubleshooting the KJ4000CV & Accessories ....................16 KJ4000LW & KJ4000CV, Oil Transfer System, OPTIONAL PRODUCTS LIST ........... 17 KJ1000 Nitrogen Intensifier ..........................18 KJ1000 Nitrogen Intensifier - Optional Products List ..................19 Mandus Group LLC Manufacturer’s Limited Warranty .................. -
Page 4: List Of Figures
KJ4000CV LIST OF FIGURES Figure A ................................10 Figure B ................................10 Figure C ................................11 Page iii 1st Edition, Rev. 0 Chg. 1... -
Page 6: General Safety Information
1. DO NOT operate the KJ4000CV or any of its components without first reading and understanding all the operating instructions first. 2. DO NOT operate the KJ4000CV unless the oil level in the reservoir is at least one inch from the bottom of the sight glass. -
Page 7: How To Use This Manual
While every effort is made to ensure the accuracy of the information contained in this manual, the Mandus Group will not, under any circumstances, be held accountable for any inaccuracies or the consequences thereof. -
Page 8: How To Use The Replacement Parts List
Serial Number WARNING The use of repair parts other than those included in the Mandus Group Replacement Parts Lists may create unsafe conditions over which the Mandus Group has no control. Such unsafe conditions can lead to accidents that may be life-threatening, cause substantial bodily injury, and/or result in damage to the equipment. -
Page 9: General Maintenance Information
5. Use the hand pump at least twice yearly. Connect the KJ4000CV to the gun, in accordance with the manual, and shift the valve to the ‘To Gun’ position. Manually pump the hand pump approximately 20 or 30 times or until you can see the reserve indicator move. -
Page 10: Operating Instructions & Parts Manual
1. DO NOT operate the KJ4000CV without reading and understanding all the operating instructions first. 2. DO NOT operate the KJ4000CV unless the oil level in the reservoir is at least one inch from the bottom of the sight gauge. -
Page 11: To Drain
2. Attach the other end of the 15 ft. discharge line (12) with the male quick connect (9) at rear of the KJ4000CV and in the upper right corner. This is the purge station (6). 3. Make sure the valve handle (3) is in the neutral position. -
Page 12: Operation Of Manual Pump
3. Always remove pump handle when pumping is completed. Changing Oil Filter Mandus Group LLC recommends changing the filter element annually. 1. When the indicator on the top of the oil filter (1) does not show green, the oil filter needs to be changed. -
Page 13: Kj4000Cv Parts List
KJ4000CV KJ4000CV PARTS LIST Dec. 13, 2022 Page 8... -
Page 14: Repair Parts List
KJ4000CV Repair Parts List Ref Number Part Number Description 1 .......... KJ4000LWMF ....Filter Assembly 2 .......... KJ4000LWPM ....Pump/Motor Assembly 3 .......... KJ4000LWVA ....Valve Assembly 4 .......... KJ4000LWMA ....Manifold Assembly 5 .......... 400077LW ...... 25 Ft. Extension Cord 6 .......... -
Page 15: Installation & User Instructions For Kj4042 Reservoir Fill Line
KJ4000CV from the pump side. 3. Feed the quick connect end of the reservoir fill line through the top of the KJ4000CV left of the shift lever (see figure B). - Page 16 KJ4000CV prior to shipping. A visible oil level in sight glass refers to 1 inch or higher. 7. If oil level is already visible in the KJ4000CV sight glass, you should be able to see the oil level rising shortly after turning on the pump.
- Page 17 KJ4000CV 9. When finished, turn pump off and disconnect from power source. Relieve any line pressure as described earlier. 10. Disconnect the Reservoir Fill Line from the pump and reconnect the KJ4000CV reservoir line to the pump. NOTICE The KJ4042 Reservoir Fill Line will drip oil from suction strainer end. Care should be taken as to how and where it is stored.
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Page 18: Instructions For Installing & Using The Kj4043Cv - Recirculation Attachment
KJ4000CV (see figure below). 3.1 Loosen discharge port valve on the M119. 4. Attach the KJ4000CV discharge hose to the recoil mechanism as described in the KJ4000CV Instruction Manual, under the set-up and operation to fill section, steps 11 thru 15. - Page 19 8. The KJ4000CV moves approximately .59 GPM of oil. You need to calculate how many times you want to turn the oil over in your system based off its volume.
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Page 20: Instructions For Using The Kj4044 - Flowmeter And Gauge Kit
The meter will track volume when the KJ4000CV is running with the valve in the “Neutral” position. You must make sure that the KJ4000CV is setup and ready to move oil with valve in the “To Gun” position prior to turning the KJ4000CV on! 3. -
Page 21: Troubleshooting The Kj4000Cv & Accessories
Reservoir doesn’t have enough oil and you are showing air volume. Inlet line from meter to pump not connected. KJ4044 flow meter display is blank. Press reset button. Batteries are dead. Contact Mandus Group LLC for replacement parts. Dec. 13, 2022 Page 16... -
Page 22: Kj4000Lw & Kj4000Cv, Oil Transfer System, Optional Products List
KJ4000CV KJ4000LW & KJ4000CV, Oil Transfer System, OPTIONAL PRODUCTS LIST Product Number Product Description System Cart - 5” High KJ1045 System Cart - 32” High KJ1046 KJ4041 Oil Releasing Tool KJ4042 Reservoir Fill Line KJ4043CV Recirculation Attachment for KJ4000CV KJ4043 (not shown) -
Page 23: Kj1000 Nitrogen Intensifier
KJ4000CV KJ1000 Nitrogen Intensifier NSN 1025-01-473-8886 The KJ1000 Nitrogen Intensifier was developed to assist the military in filling recoil mechanisms, equilibrators, or any other nitrogen-filled vessel. The KJ1000 is designed to utilize and intensify all but 150 PSI of nitrogen from a supply bottle. The KJ1000 accepts the nitrogen from a supply source, then intensifies the nitrogen source pressure by means of a hydraulic pump and electric motor. -
Page 24: Kj1000 Nitrogen Intensifier - Optional Products List
KJ4000CV KJ1000 Nitrogen Intensifier - Optional Products List Product Number Product Description System Cart – 5” high KJ1045 System Cart – 32” high KJ1046 KJ1041 Gauge Set KJ1042 Crossover Line KJ1043 Nitrogen Discharge Hose KJ1044 Tank Fill Stem KJ1047 Tank Regulator Set... - Page 25 KJ4000CV KJ1047 Tank Regulator Set – For use with 2000 PSI KJ1041 Gauge Set – For nitrogen tanks. Delivery range checking and bleeding nitro- 0 to 2500 PSI. Comes with 15 gen pressure in equilibrators ft. discharge hose to couple up and recuperators on the M198 KJ1046 32”...
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Page 26: Mandus Group Llc Manufacturer's Limited Warranty
Mandus Group LLC Manufacturer’s Limited Warranty For one year from date of purchase, Mandus Group LLC will repair or replace, at its expense and at its option, any KJ4000CV machine part, or machine accessory which in normal use has proven to be defective in workmanship or material, provided that the customer returns the product prepaid to Mandus Group LLC’s... - Page 27 KJ4000CV Dec. 13, 2022 Page 22...
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