Pkm PRO Jack Instruction manual

PRO Jack : Workshop Manual
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Workshop Manual
PRO Jack
Workshop Manual
[WM]-PKM-PRO-JACK
04/07/2022

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Workshop Manual
Table of contents
Chapt I : Disassembly................................................................................................................................ 4
1. Remove the feet ....................................................................................................................................................4
2. Depressurized the jack ..........................................................................................................................................4
3. Remove the pin and the support pin.....................................................................................................................5
4. Disassemble the handlebar ...................................................................................................................................5
5. Empty the oil..........................................................................................................................................................6
6. Disassemble the body............................................................................................................................................7
Chapt II : Assembly .................................................................................................................................. 11
1. Seal ......................................................................................................................................................................11
2. Separator piston ..................................................................................................................................................16
3. Body.....................................................................................................................................................................16
4. 16
5. Rod and tube .......................................................................................................................................................18
6. Pin........................................................................................................................................................................20
7. Pressurize............................................................................................................................................................. 20
8. Feet......................................................................................................................................................................21
9. Handlebar ............................................................................................................................................................ 21
10. Purge....................................................................................................................................................................22
11. Body Cap..............................................................................................................................................................24
Chapt III : Services..................................................................................................................................... 25
Chapt IV : Versioning................................................................................................................................. 25
Chapt V : Notes ........................................................................................................................................ 26

PRO Jack : Workshop Manual
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Workshop Manual
Flash the QR code below or follow the link to find out every information available for this product.
www.pkm-consulting.com/support/PRO-JACK/
The QR code is also on the product with his serial number.

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Workshop Manual
Chapt I : Disassembly
1. Remove the feet
Tighten the jack into the vise, you must use soft jaw to preserve the
tube.
To remove the feet, use a 8mm hexagonal key and 19 mm wrench
or adjustable plier.
2. Depressurized the jack
Unscrew the inflation screw into the rod with a Torx 20 screwdriver. Then, use a Ø0.7mm needle
to deflate the jack.

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3. Remove the pin and the support pin
Unscrew the low stop of the pin and remove support pin assembly.
4. Disassemble the handlebar
Unclip the circlip of the axle of the pump rod and retire the axle.

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Repeat this step on the connecting rod.
5. Empty the oil
Unscrew the bleed screw and set the hole down to fill out the oil on a recovery tank. Pump the
separator piston with his tool OT-EXT-002-A to fill out the oil.

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6. Disassemble the body
Unscrew check valves caps with OT-SER-192-B on the body.
Unscrew the tap cap and the pump cap from the body. Disassemble the tap from the body.

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Unscrew the screw on each side of the pump rod.
Disassemble the pump from the body. Unscrew the piston from the tube.

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Unscrew the lock nut to free the tube and then unscrew the tube from the body.
Take of the rod from the tube by the body side.
Remove the circlip and take of the separator piston from the body. Screw OT-EXT-002-A into the
separator piston to get it out.

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Remove all the seal and ring to change them.
Clean all the parts in a washing machine.

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Chapt II : Assembly
For the assembly all seals bore must be greased.
Follow the parts list to use the right tool, with the right torque and Loctite for all parts.
To purge your jack correctly you must use an automatic bleeding machine.
You must use PK-OIL-001-A to fill up the jack.
1. Seal
To begin the assembly, you must set all the seal and back-up ring on the different parts, do not
forget to grease the seal :
a) The pump cap
Put X-ring JS0066 and the back-up ring JS0084 against the ring (PK-BAG-057-A) that you do not
need to remove. Then insert the second JS0066.
Put the O-ring J01800200F outside the Cap.

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b) Pump Piston :
Insert the X-ring JS0079 with backup ring JS0068 on each side. Replace the piston band
PK-BAN-034-A
c) Pump rod
Insert the washer JA-RON-003-A on the rod.

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-Press the rod assembly into the previously cap.
-Lock the rod assembly into OT-MOR-029-A
-Screw the piston JA-PIS-005-A on the rod with Loctite 243
at 8N.m.
d) The tap
On the cap JA-BOU-018-A insert J01400200N and (N) O-ring.
Screw the rod JA-TIG-009-B through the cap with O-ring J00550160F inside it.

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e) The separator piston
Insert the O-ring J05400500N around the separator piston.
f) Tube
Insert, in this exact order JA-RON-001-A, JS0069,JS0074, JA-RON-004-A into the tube and grease
them. Then clip the circlip PK-JNC-061-A and finally insert the wiper seal JS0076.

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g) Rod piston
Install piston band PK-BAN-035-A, back-up ring JS0071 and O-ring J02400400N onto the piston
JA-PIS-001-D.

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2. Separator piston
-Grease the piston JA-PIS-004-C with his seal and set it into the body greased too.
-Do not forget the circlips PK-JNC-095-A before purge.
3. Body
4.
Screw the two CHC050N005E109 screw with their copper seal JC0002 with Loctite 577 at 8N.m.

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Set the pump rod into the body after greasing it. Screw the cap JA-BOU-016-A into the body at
20N.m with OT-CLE-003-B.
Set the tap assembly into the body. Screw the cap JA-BOU-018-A tap into the body with Loctite
243 at 20N.m TOOOl. Screw the rod JA-TIG-009-B at the maximum to close the tap. Set the scroll
wheel onto this axle at 45°. Screw HC040N006E109A with Loctite 243.

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Screw all the cap JA-BOU-001-D and JA-BOU-008-A with OT-SER-192-B at 20N.m.
5. Rod and tube
Insert the rod into the tube through the body side with OT-CON-015-A. Push with OT-SER-019-A.

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Screw the tube into the body until the end of the thread with Loctite 243. Unscrew the tube to
align the pin with the bleeding screw.
Lock the locknut JA-ECR-001-B to the body with Loctite 243 at 35N.m with OT-SER-193-A.

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6. Pin
Insert the pin subset on the tube and screw the low stop screw CHC040N006E109 with Loctite 243
at 6N.m.
7. Pressurize
Pressurize the jack through the bottom of the rod with a needle at 20bar and tight up the
screw BHC040N006E1409 with his O-ring J00450150N.