Dualco 12000 User manual

Instructions
12000 Air/Hydraulic
Injection Gun
Model
Page 1 of 3
Parts Diagram
Frame
Handle - Piston Return
Tube / Cap Wrench
Quick Connect
Coupler
Air Line Inlet
Connection
Safety First!
Use only Genuine Dualco Parts.
Contact Dualco for repair, or rebuilding
procedures.
Lubrication Hose
Outlet Connection
Pump Pedal
Pressure Gauge
Barrel
Piston
Barrel Cap
Pump Cylinder

Instructions
12000 Air/Hydraulic
Injection Gun
Model
Read complete instructions
before using this Gun.
Page 2 of 3
All models of the DUALCO Air Hydraulic Injection Gun are
high-pressure tools that should be used with caution and
according to these instructions.
IMPORTANT - This Gun is 10,000 psi rated. Do not exceed
10,000 psi.
The (numbers) shown herein refer to the Parts List on page 3
and in Brochure 363-898.
These Injection Guns transmit material by the use of
compressed air as a power source against pressurized hydraulic
fluid. One end of DUALCO Injection Gun is the Pump containing
hydraulic fluid.The other end of the Gun is the Grease Barrel.
The Barrel and the Pump are separated by the Gun Body), Hose,
and other components. During operation, air pressure forces
hydraulic fluid from the Pump through the Hose and Body into
the space behind the Piston located in the Grease Barrel. The
Piston pushes the material out through the Grease Barrel Cap.
Numerous options are available for Grease Barrel Cap
attachments to transmit material to the desired pump, valve, or
other equipment.
A. To activate the Pump and extend the Pump Cylinder,
depress the pedal on the marked end.
B. To hold the Pump cylinder in position, release the marked
foot pedal to deactivate Pump.
C. To deactivate the Pump and retract the Pump cylinder,
depress the marked foot pedal end.
Note: These instructions refer to Power Team Forms 101652
and 105001.
The Handle has a side hole near the threaded end, which will fit
over the pin in the Grease Barrel Cap. Using the Handle in this
manner makes it a convenient tool to loosen and tighten the
Cap. The Handle is marked with approximate 1-ounce
graduations for measuring material.The Handle can be used for
pushing the Piston to bottom of Grease Barrel.
To ensure the DUALCO Air Hydraulic Injection Gun will perform
and operate properly, use after use, keep the gun out of the
weather, clean, and maintained.
Part 1. Operation & Description
Pictogram Definitions
Activating the Pump with the pedal end marked with a
pictogram, the flow of Pump fluid is directed
out of the reservoir.
Activating the Pump with the pedal end marked with a
pictogram, the flow of Pump fluid is directed back to the
reservoir.
Under certain circumstances, it may be necessary to prime
the Pump, following this procedure:
A. Press the release end of the pedal while holding down the
air intake valve with a flathead screwdriver. The air intake valve
is located directly under the pedal in the area marked.The valve
is depressed simultaneously with the
area of the pedal during priming.
B. Allow the Pump to cycle approximately 15 seconds.
C. Remove the screwdriver, and press the end of the pedal once
more.
D. If the Pump cylinder extends or pressure builds, the Pump
has been successfully primed. If the Pump does not respond,
repeat the procedure, jogging the air intake valve while holding
the pedal in the active position.
Part 2. Priming the Pump
Each new DUALCO Air Hydraulic Injection Gun is ready to use,
following this procedure:
A. Make sure the Pump cylinder is retracted and the Pump is
deactivated and all pressure is released.
B. Remove Grease Barrel Cap with Handle as previously
described in I.
C. Using Handle, push Piston Assembly to bottom of Grease
Barrel so it will be flush against Body.
D. For this Model, use an optional Wooden Dowel to push
Piston Assembly to bottom of Grease Barrel.
E. Load the Barrel with material (Lubricant, Packing, Sealant, or
Cleaner), in either bulk, prepackaged or stick.
F. Replace Grease Barrel Cap and tighten with Handle.
G. Replace Handle onto Body and the Gun is ready to operate.
Be sure to have the appropriate material transmission apparatus
or hose assembly firmly attached to the Grease Barrel Cap.
IMPORTANT - Always make sure the Grease Barrel Cap is firmly
attached to the Grease Barrel and be sure there is full thread
engagement between these two parts before Gun operation.
•Optional Parts and Tools, including in-line Air Filter/Lubricator
and Carrying Unit, may be available.
Part 3. Loading

Instructions
12000 Air/Hydraulic
Injection Gun
Model
DUALCO • 8404 Braniff, Houston, Texas 77061
713-644-1164 • FAX [phone]
www.dualco-inc.com
E-Mail: [email protected]
Manufacturers of
Professional Lubrication
Equipment since 1960
Made in USA
All Rights Reserved. © Copyright 2018 DUALCO Inc.
Page 3 of 3
Part 4. Maintenance
Any repair or servicing that requires disassembly of the DUALCO
Injection Gun must be performed in a dirt-free environment by
a qualified technician. Dispose of used parts and fluids properly.
Item 1. Injection Fluid
The DUALCO Air Hydraulic Injection Gun comes filled with
DUALCO Injection Fluid. Fluid should be added or replaced as
necessary using only DUALCO Injection Fluid. Do not
contaminate or use any other fluid. Check the fluid level in the
Pump reservoir after every 10 hours of use. Drain and replenish
the Pump reservoir with DUALCO Injection Fluid after every 300
hours of use.The fluid is available in several size containers up
to 55-gallon drums.
Item 2. Refilling the DUALCO Air Hydraulic Injection Gun Pump
with Injection Fluid and Purging the system of air
A. During the first moments of operation or after prolonged
use, a significant amount of air may accumulate within the
system.This entrapped air may cause the cylinder to respond
slowly or behave in an unstable manner.To remove the air, run
the system through several cycles (extending and retracting the
cylinder) free of any load.The cylinder must be at lower level
than the Pump to allow air to be released through the Pump
reservoir.
B. Clean the entire area around the Pump filler plug before
adding fluid to the Pump reservoir. Remove the Pump filler plug,
and insert a clean funnel with filter. The cylinder must be fully
retracted and the air supply disconnected when adding the
fluid to the Pump reservoir.
Item 3. Lubrication
If the Gun is operated on continuous cycles for extended
periods, it is recommended that an automatic Air
Filter/Lubricator be installed on the air inlet line as close to the
Pump as possible. Set the Lubricator to feed approximately one
drop of oil per minute into the system. Use SAE No. 10 oil.
Item 4. Periodic Cleaning
IMPORTANT - The greatest single cause of failure in hydraulic
pumps is dirt. Keep the Pump and attached equipment clean to
prevent foreign matter from entering the system.
A routine should be established to keep the Pump as free from
dirt as possible. All unused couplers must be sealed with thread
protectors. All hose connections must be free of grit and grime.
Any equipment hooked up to the Pump should also be kept
clean. Use only DUALCO Injection Fluid in this Pump and change
as recommended (every 300 hours).
Item 5. Draining and Flushing the Pump Reservoir
IMPORTANT - Wipe the Pump exterior completely clean before
attempting this procedure!
A. Remove the screws that fasten the Pump assembly to the
reservoir. Remove the Pump assembly from the reservoir. Do not
damage the gasket, filter, or safety valve.
B. Drain the reservoir of all fluid and refill half full with clean
injection fluid. Rinse the filter clean.
C. Place the Pump assembly back onto the reservoir, and secure
with two of the machine screws assembled in opposite corners
of the housing.
D. Run the unit for several minutes. Use the same method
described in the section titled “Priming the Pump.”
E. Drain and clean the reservoir once more.
F. Refill the reservoir with DUALCO Injection Fluid and replace
the Pump assembly (with gasket) on the reservoir and install
the screws.Torque the screws to 25 to 30 inch pounds (2.8 to 3.4
N•m).
IMPORTANT - Warranty will be voided if the Pump
Internal Relief Valve or other Gun components are
altered, disassembled, or tampered with.
IMPORTANT - Drain and clean the other hydraulic
system components (hoses, cylinders, etc.) before
reconnecting them to the Pump.This will prevent
contaminated fluid from entering the Pump again.
Note:
Contact DUALCO for other operation, repair,
or rebuilding procedures.
WARNING - Read Material Safety Data Sheet
and DUALCO Injection Fluid label before use.