Installation Instructions Revision F 08/01/2016 page 1 of 18 Safety Warning, Terms and Conditions: Each P-Rod Double kit has been designed, manufactured, and tested to function with a standard Benjamin Marauder air pistol. Warning! Make sure airgun is fully degassed before attempting dis-assembly or installation. As Airgun Lab, LLC, cannot supervise the installation or usage of the kit, it can make no warranties other than material and workmanship. Warranty and Limitations of Liability Airgun Lab, LLC, warrants the kit against defects in material and workmanship for 30 days. If you are not satisfied with the kit, pending prior approval, it may be returned at your own shipping expense within 30 days for a full refund. In no event will Airgun Lab, LLC, be liable for any damages, whether direct, indirect, incidental or consequential, arising out of the use or inability to use the kit. Purchasing the kit implies agreement with these terms. IMPORTANT - PCP Assembly Skill is Required for Proper Installation of the Kit For the best results, installation of this kit should only be performed by someone with experience working on PCP airguns. Attention to detail is vital. Experience with using Teflon tape on high pressure threaded fittings, and understanding the installation, fit, feel, and lubrication of o-rings is important. Improper installation can damage parts and result in a failed installation. Although most installations are trouble-free, occasionally leaks may occur and troubleshooting will be needed. A trouble shooting guide can be found at the end of these instructions. Rear plug The Standard Kit Fore grip screw Air tube (chrome moly standard, aluminum optional) Air transfer fitting with securing screw Spare o-rings Front plug & new gage adapter Standard floating barrel band (3 different clamping bands are optional) The items shown are included in the base price. Clockwise from the top: the chrome moly air tube (1 diameter x.065 wall x 10-5/8 wall, 81ccs) with rear plug and fore grip screw installed; the standard floating barrel band; the front pressure gauge adapter; the spare o-rings and lube; the air transfer fitting and its securing screw.
Installation Instructions Revision F 08/01/2016 page 2 of 18 The Five Barrel Band Choices Bands, from the left: standard floating (included in the kit at no extra cost), Optional plain clamping band, Optional clamping band with Picatinny rail on the bottom, Optional clamping band sight blade, Optional clamping band modified for TKO moderator. The TKO moderator will work with the full floating band as-is. With a minor modification, available from the Airgun Lab, any of the clamping barrel bands can be modified to fit the TKO. There is an additional charge for each of the clamping bands, and for the TKO modification.
Installation Instructions Revision F 08/01/2016 page 3 of 18 Placement of the Standard Floating Barrel Band floating band can be shifted along the length Above, is a completed installation with the standard floating barrel band, and the optional black foregrip. The floating band may be positioned anywhere along the front end of the tubes as indicated by the red arrow. Placement of All Optional Clamping Barrel Bands All of the clamping style bands must be pushed tight against the fill adapter Above, is a completed installation, with the optional unfinished poplar foregrip, stained and varnished by the customer. This pistol has the optional clamping barrel band with front sight blade. All of the clamping bands must be positioned tightly against the front end of the fill adapter as shown by the red line and arrow. IMPORTANT - The position of the clamping style of bands cannot be shifted along the length of the tubes.
Installation Instructions Revision F 08/01/2016 page 4 of 18 Foregrips required option The foregrips are an integral structural element in the P-Rod Double assembly. The 1 diameter hole through the middle, and the special contouring to fit the main tube of the gun, and to fit the front of the pistol grip assembly, all help to safely secure and stabilize the gun and tubes. This picture shows the special fit of the new foregrip. Below, are some foregrips that are available from the Airgun Lab. Availability is variable.
Installation Instructions Revision F 08/01/2016 page 5 of 18 Tactical Look - optional Here is a picture of the P-Rod with the P-Rod Double kit and the optional RAI adjustable adapter for an AR buttstock. This is the same, with the folding hinge installed and the P-Rod folded to a more compact size.
Installation Instructions Revision F 08/01/2016 page 6 of 18 TKO Moderator Optional (must be purchased an installed by the buyer.) Here is a picture of the P-Rod with the TKO moderator installed. The barrel band needs to be modified for installation of the TKO. That service is offered by The Airgun Lab.
Installation Instructions Revision F 08/01/2016 page 7 of 18 Tools and materials O-ring reference guide two complete sets of o-rings are included in the kit. One set is installed, and the other is packed in a plastic bag. o Transfer fitting (qty 2) Metric size 2 X 7 duro 70 (nominal 7mm I.D. x 11mm O.D. x 2mm cross section) (nominal.275 I.D. x.433 O.D. x.079 cross section) o End plugs for aluminum tube (qty 2) size 114 duro 70 or 90 (nominal 5/8 I.D. x 13/16 O.D. x 3/32 cross section) o End plugs for chrome moly tube(qty 2) size 115 duro 70 or 90 (nominal 11/16 I.D. x 7/8 O.D. x 3/32 cross section) o Pressure gauge adapter inside main tube (qty 2) size 113 duro 70 or 90 (nominal 9/16 I.D. x 3/4 O.D. x 3/32 cross section) Note- these o-rings are in the bag and would only be used to cure a leak inside the main tube of the pistol. They might be needed. o Trim o-ring for the front plug of the new air tube (qty 1) size 115 duro 70 (nominal 11/16 I.D. x 7/8 O.D. x 3/32 cross section) o O-ring silicone grease not included in the kit. CAUTION - USE ONLY Silicone grease or silicone o-ring lube. DO NOT use a petroleum based grease because it is combustible and could cause an explosion. o Teflon pipe joint tape not included in the kit. Available in the plumbing department of any hardware or home improvement store. Tools Adjustable wrench (8 or 10 ) to fit the pressure gauge (approx 1 across the flats). 5/16 or 8mm open end wrench for tightening the air transfer fitting (DO NOT use an adjustable wrench (Cresent wrench) because it is too wide and will damage the fitting). 5/8 or 16mm open end wrench to hold the new tube front plug (an adjustable wrench is too wide and will NOT work). 1/8 Allen wrench (hex key) for new 10-32 button head screws. 5/64 Allen wrench (hex key) for set screws in the bottom of the barrel bands. 7/64 Allen wrench (hex key) for socket head cross screws in the clamping barrel bands. calipers or precision metal 6 scale for measuring transfer fitting height.
Installation Instructions Revision F 08/01/2016 page 8 of 18 Installation instructions WARNING ALL HIGH PRESSURE AIR MUST BE REMOVED FROM THE AIR GUN BEFORE ATTEMPTING THE INSTALLATION. FAILURE TO DO SO COULD RESULT IN SERIOUS INJURY OR DEATH. IMPORTANT IF YOU ARE NOT CONFIDENT IN YOUR ABILITY TO SAFELY INSTALL THIS KIT, CONTACT THE AIRGUN LAB TO ARRANGE FOR QUALIFIED INSTALLATION. 1) Degas the air gun to remove all high pressure air. 2) Remove the plastic foregrip. The plastic foregrip will not be reused. 3) Remove the barrel band. The barrel band will not be reused.
Installation Instructions Revision F 08/01/2016 page 9 of 18 4) Remove the gauge from the air tube. WARNING if any pressurized air remains in the tube, the gauge will blown very dangerously from the tube. 5)Install the gauge into the new adapter as follows: Wrap the gauge threads with Teflon tape (not supplied with the kit). The Teflon tape is available in white, yellow, green, and pink. They are all the same except for thickness, with the white being the thinnest. Any of the tapes will work, but the yellow, green, or pink might be easier to work with, or work better to seal a troublesome leak. 6) Install the gauge into the new adapter. Use a 5/8 wrench to turn the adapter while holding the gauge with a crescent wrench. Tighten it snugly, but the gauge does not have to bottom out hard against the adapter. Be careful, do not overtighten and damage the gauge. IMPORTANT Do not damage the o-ring groove or the threads of the adapter.
Installation Instructions Revision F 08/01/2016 page 10 of 18 7) Install the trim o-ring (size 115) into the gap between the adapter and the gauge. Stretch it into place and then adjust for a neat appearance. 8) Install the gauge into the open end of the new tube as follows: If not already installed, install the proper size 114 or 115, duro 70 or 90 o-ring into the groove in the adapter. Lube the o-rings and mouth of the tube with o-ring lube. 9) Thread the adapter into the tube. Do not cross thread. A wrench should not be needed for this. You will feel friction from the o-ring, but if it is difficult to start, back it out and try again. When the adapter is about 3/16 from being all the way in, it will engage the sealing diameter in the tube and become difficult to screw in. You will feel it pop into place. Thread the adapter into the tube as far as it will go, stopping when the bottom of the gauge face lines up with the Fore Grip Screw at the other end of the tube and the size 115 trim o-ring is still visible between the gage and the tube. Note that when the gun is fully pressurized, the gauge cannot be twisted into alignment.
Installation Instructions Revision F 08/01/2016 page 11 of 18 10) Install the air transfer fitting next. Remove the 10-32 x 5/16 Button head screw that is in the end of the transfer fitting, and save it for installation later. Check the hole in the air tube to make sure it is clean. It must be free from debris. Use a vacuum, dental pick, tweezers, etc, to clean it out. Dry fit the tube transfer fitting (without Teflon tape) into the hole in the tube. It should go in about two threads. Remove the fitting and wrap it with at least 4 turns of Teflon tape as shown. It is OK to wrap the tape into the groove adjacent to the threads, but Do Not overlap the tape into the two o-ring grooves. 11) Using a good quality 5/16 or 8mm wrench, carefully and firmly tighten the transfer fitting. It does not matter where the small hole in the side of the fitting ends up. When the fitting is partially tight, check its height. It must finish up at 0.790 to 0.840 tall. If it is too tall, tighten it more. If it is too short, take it out and use more wraps of Teflon tape. DO NOT use an adjustable wrench on this fitting as the sealing surfaces might get damaged. IMPORTANT After installation, feel the fitting where the wrench was applied, for any burrs or raised areas. If there is damage, remove the damage with a jewelers file. If you don t, it will scratch the mating port in the tube and leak. Critical dimension -.790 to.840 from high point on the tube to the top of the fitting.
Installation Instructions Revision F 08/01/2016 page 12 of 18 12)Install the new tube as follows: If not already installed, install the two Metric size 2mm x 7mm duro 70 o-rings into the two grooves in the transfer fitting. Verify that there is plenty of the lube on the o-rings and in the deep hole and its entrance mouth in the tube. 13) Very carefully push the new tube onto the adapter. Gently wiggle it from side to side while applying firm pressure until the tube pops on. It is easier to do when the new tube is more perpendicular to the main tube as shown. Keep pushing and wiggling the tube until it seats all the way down. The second o-ring might seat into the rear plug with a pop.
Installation Instructions Revision F 08/01/2016 page 13 of 18 14) Use the 10-32 x 5/16 button head screw that was removed earlier from the end of the transfer fitting to secure new tube to the transfer fitting. Gently snug the screw down. DO NOT over-tighten. This screw carries almost no load from the high pressure air, and overtightening it can cause a leak. WARNING EVEN THOUGH THIS SCREW CARRIES ALMOST NO LOAD, FAILURE TO INSTALL IT WILL ALLOW THE TUBE TO COME OFF UNEXPECTEDLY WHICH COULD RESULT IN SERIOUS INJURY OR DEATH. 15) After the screw is snugged up, Inspect for a very slight gap between the two tubes. The optimal situation is for a gap just large enough to slip a piece of paper through, but a gap the thickness of a credit card is OK, too. If the gap is too large, the fore grip and tubes might not tighten up together properly. If there is no gap between the tubes and tightening the 10-32x5/16 screw jammed the tubes tight together, a leak past the o-rings of the old gage adapter in the main tube might occur. If a leak in this area occurs during initial fill-up with air, the threaded height of the air transfer fitting (.790 to.840 ) might need to be adjusted. Gap After tightening the transfer fitting screw on the bottom, a very thin gap should be visible between the two tubes. Screw
Installation Instructions Revision F 08/01/2016 page 14 of 18 16) Check the installation for security at all fittings. Align the tubes. Slide the barrel band into place, but do not secure it with set screws. Connect an air source to the quick disconnect fitting and SLOWLY bring the pressure to about 700 psi. Stop, and listen for leaks. If there is a leak, go to the Leak section at the end. Otherwise, check, and adjust, the alignment of the 3 tubes to each other and continue filling to full pressure. NOTE- The alignment of the three tubes must be checked at the muzzle end, AND also at the breech end. They must all be parallel to each other and not just twisted into alignment. As the air pressure increases, it will become difficult to fix any misalignment, so do it while the pressure is low. Visually align the 3 tubes at the front end, as shown, and also at the trigger end, too. Misalignments are difficult to correct after the gun is fully pressurized. Caution A Note about installing any of the clamping barrel bands: Do not install the two 6-32x7/8 cross screws into the clamping barrel bands until after the band is snapped securely into place and seated tight against the shoulder of the fill adapter. The screws fit into the grooves on the fill adapter and cannot align properly until the band is seated all the way on.
Installation Instructions Revision F 08/01/2016 page 15 of 18 17) Final assembly If the barrel band is on, remove it. Install the fore grip by sliding it on from the front. It is an integral part of the tube alignment system and requires a snug fit. If it is too snug you may lightly sand out the hole within the fore grip to optimize the fit. 18) Secure the fore grip with the 10-32 x 9/16 button head screw provided. Slide the barrel band back into place, but do not tighten. 19) Final alignment. With the barrel band installed, but not secured, check the alignment of the 3 tubes to each other. The alignment of the three tubes must be checked at the muzzle end, AND also at the breech end. They must all be parallel to each other and not just twisted into alignment. As the air pressure increases in the tubes, it will become difficult to fix any misalignment, so do it while the pressure is low. When satisfied with the alignment, tighten the set screws, (or clamping screws with the clamping bands), in the barrel band.
Installation Instructions Revision F 08/01/2016 page 16 of 18 20) Bring it up slowly to full pressure and try it out! LEAKS What to do? In no particular order: 1) At the threads of the air pressure gauge where it threads into the front tube adapter. The fix- Remove the gauge and adapter from the gun. Un-thread the gauge. Remove all Teflon tape residue. Reassembly using either pink or yellow Teflon tape, or more wraps of the white tape. 2) A leak where the new transfer adapter threads into the old gauge adapter. The Fix Use the same procedure as leak number one. 3) A leak from inside the port that the transfer fitting slips into. This is most likely an o-ring that was damaged during assembly, or the hole in the rear fitting was scratched when the transfer fitting was pushed in. The Fix Disassemble, check for any burrs or o-ring damage, polish the surfaces, and replace the o-rings. 4) A leak from the old o-rings on the old gauge adapter. This can occur when the 10-32 screw securing the new tube to the transfer fitting is over-tightened. This might be difficult to detect, and the transfer tube is likely to be blamed. To help diagnose the leak, tighten and loosen the 10-32 screw that holds the new tube to the transfer adapter. If the sound of the leak changes as the 10-32 screw is tightened and loosened, then you have found the leak. It will be necessary to remove the gauge adapter from the main air tube and install new o-rings. The actual cause of this leak is old o-rings on the gauge adapter fitting that have taken a set and are no longer flexible enough to respond to the side load that can be imparted by the new transfer adapter. NOTE- Size 113 o-rings are included in the kit in case the o-rings on the gauge adapter need to be replaced.
Installation Instructions Revision F 08/01/2016 page 17 of 18 More Leak Troubleshooting
Installation Instructions Revision F 08/01/2016 page 18 of 18