Ped Series

7/27/2019 Ped Series

1/20

Operating & Maintenance InstructionsElectric Dump Pumps.

PED SERIES

The world's most complete line of industrial, hydraulic andmechanical lifting and positioning equipment.

SIMPLEX DIVISION OF TEMPLETON, KENLY & CO., INC.2525 Gardner Road Broadview, Illinois 60155 (708) 865-1500 / Fax (708) 865-0894www.tksimplex.com

HYDRAULIC & M ECHANICAL POWER

Part Sheet #: 54394Revised: 4-00

SERV

ING

INDUSTRYW

ITHPRID

E

QUALITY

Templeton Kenly& Co.,

Inc.

SINCE - 189 9

EQUIPM

ENT SE

RVICEASSOCIATIO

N

REBUILDERSOFTOOLS & EQUIPME

NTUSA

MEMBERCANA

DA

ELECTRIC DUM P PUM PS


2/20

OPERATING INSTRUCTIONS AT A GLANCE

Before Operating Pump:

1. Be sure the electrical connection is grounded. Check that your power supply agreeswith the motor nameplate.

2. Use only cylinders, hoses and equipment rated at 10,000 PSI.

3. Make sure all hose and fitting connections are tight and secure. Hoses cannot bekinked or twisted.

4. Oil level should be 1 to 2" from the top of the reservoir plate, with cylinders retractedand motor off.

5. Never operate the pump with the directional control valve in advance or retract at10,000 PSI without ram movement for more than 1 minute. Leaving the valve in the

advance or retract position without the rams piston rod moving will overheat the oil.

After Completing the Job:

1. Before disconnecting hoses, fittings, etc., first be sure the ram is retracted & unloaded,then unplug the power cord and shift the hydraulic controls several times to releasesystempressure.

2. Store the pump in a clean, dry area.

Periodic Maintenance:

1. Completely change the hydraulic oil and clean the oil filter screen and magnet (locatedin the reservoir) twice a year. (Use Simplex oil only, Model # AO1, 1 gallon). Changethe oil more frequently when used in extremely dusty areas or when the oil has beenoverheated. Using oil other than Simplex Brand voids the pumps warranty.

-1-


3/20

SECTION I

SAFETY

1-1. Working Pressure

The pump's maximum working pressure is 10,000 PSI (700 kg/cm2). Make sure that all hy-

draulic equipment such as rams, hoses, etc. used with this pump are rated at 10,000 PSIoperating pressure.

1-2. Hydraulic Connections

Never disconnect or connect any hydraulic hoses or fittings without first unloading the ram,then unplug the electrical cord of the pump and shift, or open all hydraulic controls severaltimes to assure that the system has been depressurized. If the system includes a gauge,double check the gauge to assure pressure has been released.

When making connections with quick disconnect couplings, make sure the couplings are fullyengaged. Threaded connections such as fittings, gauges, etc. must be securely tightenedand leak free.

CAUTION: Loose or improperly threaded fittings can be potentially dangerous if pressurized,however, severe over tightening can cause premature thread failure. Fittings need to betightened secure & leak free. Never hold or stand directly in line with any hydraulic connec-tions while pressurizing. Never grab, touch or in any way come in contact with a hydraulicpressure leak. Escaping oil can penetrate the skin and a serious injury can result.

*Do not subject the hose to potential hazard such as sharp surfaces, extreme heat or heavyimpact. Do not allow the hose to kink & twist. Inspect each hose for wear before it is used.

1-3. Electrical Power

1. CHECK FOR PROPER ELECTRICAL SUPPLY BEFORE CONNECTING.

2. THIS MOTOR MAY SPARK. DO NOT OPERATE IN AN EXPLOSIVEATMOSPHERE OR IN THE PRESENCE OF CONDUCTIVE LIQUIDS.a. Do not use a power or extension cord that is damaged or has exposed wiring.b. All single phase motors come equipped with a three prong grounding type plug

to fit the proper grounded type electrical outlet. Do not use a two prongungrounded extension cord as the pump's motor must be grounded.

1-4. Jacking Safely

You must know the weight of what you intend to lift and choose a ram with at least 10% morecapacity.

The ram should be placed on a solid foundation so that the base of the ram is fully supported.The load must be centered on the ram, or equally distributed on multiple rams. Off centerloading can result in the ram slipping out and loss of the load.

Never crawl or place any part of your body under any load at any time. Insert blocking orcribbing under the load as you lift. Hydraulic rams are meant for lifting only and should not beused to support the load for any period of time.

You should obtain and be familiar with the American National Standards Institute rules thatapply to hydraulic rams and jacks (ANSI B30.1).

-2-

!


4/20

SECTION II

INSTRUCTIONS BEFORE USE

Read carefully. Most malfunctions in new equipment are the result of improper operationand/or improper set-up assembly.

Preparation: Remove pump from shipping container -- but do not remove any plugs orvalves until the unit is ready to be fully assembled to prevent dirt or foreign matter fromcontaminating system.

Inspection: Visually inspect all components for shipping damage. If any damage is found,notify carrier immediately.

2-1. Electrical Connections:

Compare motor nameplate against power availability to prevent motor burnout or dangerouselectrical overloading.

Minimize the length of extension cords and be sure they are of adequate wire size, withgrounded connections.

0.5H.P., 115Vup to 50' 12-3 gage

2-2. Hydraulic Connections:

Check hydraulic oil level to prevent possible pump burnout. Open the red plastic fill plug

located on reservoir plate. Oil level should be approximately 2" from top of reservoir plate --

with cylinders retracted and motor off. Add Simplex oil as necessary. Do not mix differentgrades of oil.

Make sure all desired gauge, valve, hose and quick coupler connections are tight and securebefore operating (See Section 1.2). The pumps pressure ports are 3/8 NPTF and are located

just below the control valve. (See Section 3-1).

The use of a pressure gauge is strongly recommended for normal operation of these pumpsand required when the external adjustable relief valve pressures are changed. Mounted on agauge adapter between the pump and cylinder, the gauge permits the operator to monitor

loads on cylinders.

Do not exceed rated capacity of equipment connected to pump. Where shock loading or

unsteady loads may cause overloading of cylinders, the operator must use larger capacitycylinders to provide additional operating margin.

-3-


5/20

SECTION III

OPERATION

3-1. Control Valves:

a. 2-Way Valve for Single Acting Rams

To Advance.........turn lever to the right& start motor.

To Hold................turn motor off.To Retract............turn lever to the left.

b. 3-Way Valve for Single Acting Rams

To Advance..........push lever to right.For Neutral/Hold...place lever in middle.

To Retract.............push lever to left.

c. 4-Way Valve for Double Acting Rams

Pushing lever to right directs pump outputto right-hand port.Pushing lever to left directs pump output to

left-hand port.Center position is neutral/hold. Pumpoutput is directed back to tank.

3-2.. Before starting pump, place valve in Neutral/Hold position (as described above) to preventaccidental lifting or moving of load. Start the pump and let the pump idle for a few minutes.

3-3. Bleeding the Hydraulic System--air can be removed from the system by fully advancing andretracting the hydraulic cylinder several times with the pump elevated so its reservoir is higherthan the cylinder. Single-acting cylinder should be inverted, and double-acting on their side

with the coupling fitting up. When the trapped air is removed from the hydraulic circuit, thecylinder will advance and retract smoothly. Sluggish cylinder action is usually the first sign ofair in the system.

3-4. Move lever to Advance position (as described above) to activate ram or cylinder. To holdload, place lever into Neutral/Hold. Move lever to Retract position (as described above) torelease load.

3-5. Never operate the pump at 10,000 PSI without ram movement for more than 1 minute withoutshifting the control valve to neutral. Leaving the valve in the advance or retract positionwithout the piston rod moving will overheat the oil.

* Useable 3/8 NPTF port

*

* A

* A

* A

* A

B *

B *

Return ports

only.(Marked T)

-4-


6/20

SECTION IV

MAINTENANCE

WARNING: THE ELECTRICAL POWER CORD MUST BE DISCONNECTED FROM ELEC-TRICAL OUTLETS BEFORE PERFORMING MAINTENANCE OR REPAIR

PROCEDURES.

4-1. Maintain Oil Level -- check hydraulic oil level every 30 hours of operation. Add Simplex oil(Model # AO1 -- 1 gallon) when necessary. Oil level should be no more than 2" from top of

reservoir plate -- with cylinders retracted and motor off.

Completely change oil at least twice a year. The following conditions require more frequent

oil changes:a. Rigorous duty, where oil temperature may reach 140 F.b. High humidity environment and extreme changes in temperature that can result in con-

densation inside the reservoir.

c. Dirty or dusty environments that may contaminate the oil.

4-2. Clean Oil Filter Screen Once a Year

a. Loosen and remove reservoir plate bolts. Lift pump unit off the reservoir, being careful notto damage the gasket.

b. Unscrew screen from bottom of pump unit and clean with nonflammable solvent.

c. Blow dry and reassemble.

4-3. Keep areas around pump unobstructed to provide good air flow around the motor and pump.Keep the motor and pump as clean as possible.

4-4. Adjusting the External Relief Valve:

a. Install gauge and gauge adapter between pump and cylinder.b. Remove cover to expose adjusting screw. Place valve lever in Neutral/Hold position and

start motor. Move lever to direct pump output to pressure port (Advance).c. Insert allen wrench into adjusting screw in the hole on the lower left side of valve.

d. Turn adjusting screw clockwise to increase, or counter clockwise to decrease pressure .(Do not exceed 10,000 PSI.)

e. Check valve setting by shifting the valve to advance and retract cylinder several times.Maximum gauge reading should remain constant.

4-5. Flushing the Pump. If you suspect your pump has been contaminated or discover sludge orother deposits on internal components, you should thoroughly flush the pump.

a. Remove the old oil from the reservoir, then thoroughly clean the reservoir and refill with aclean, nonflammable flushing oil.

b. Reassemble the pump and motor to the reservoir.c. Now run the pump in no load condition for 1 or 2 minutes maximum.

d. Unplug the pump and remove the motor and pump assembly again. Now drain the flush-ing oil and reclean the inside of the reservoir. (Make sure flushing fluid is also drainedfrom pump assembly). Refill the reservoir with Simplex hydraulic oil and reassemblethe pump.

-5-


7/20

SECTION V

TROUBLESHOOTING

If the procedures listed below do not remedy the problem -- the pump will requireservice and should be taken to an authorized Simplex service center for repair

Problem Cause -- Solution

Sporadic Cylinder Action

Motor Will Not Start

Noisy Operation

Pump Oil is Over Heating

Pump Runs but Will Not Pump Oil

1. Air in the hydraulic system. See Sec. 3-3 forcorrect bleeding procedure.

2. Check reservoir oil level.

Be sure power cord is not damaged. Check for

tripped circuit breaker--be sure breaker is of ad-equate size. Have qualified electrician inspect forloose or faulty wiring. Have motor checked fordefective motor capacitor. Be sure electrical supply

and extension cords are adequate.

1. Air in system. (See Sec. 3-3 for bleeding

procedure).2. Be sure the oil reservoir is filled to normal level.3. Check all points where air might leak into

system.

1. Oil viscosity too high. Replace with Simplex #9.

2. Check for high pressure leakage on upperpressure plate. (Leaking at plug).

3. Oil level is low. Fill reservoir to normal level, orrefit the pump with larger reservoir.

4. (See Section 3-5)

1. Pump is not primed. Run pump a few minutestipping from side to side.

2. Check to make sure that externally adjustablerelief valve set properly.

Check internal relief valve.3. Damaged O-Rings. Take to nearest Simplex

service center for repair.

4. Defective control valve. (Troubleshootseparately).

-6-


8/20


9/20

PUMP ASSEMBLIES69118

DISCRIPTION

BearingRetaining RingPIpe PlugExt. Relief SeatExt. Relief ConeValve Relief SpringAdjust ScrewBall 3/16"SpringPiston Block .210SHCS 5/16-24x1.7Dump PistonSealO-RingLever-DumpPinRetaining RingSOC Set ScrewNut-Self LockingSpringCone

SeatBackup WasherO-RingSHCS 5/16-24x5/8

QTY.

311111111361111121111

1116

ITEM

444546474849505152535455565758596061626364

65666768

ITEM

123456789

101112131415161718192021

222324252627282930313235

36373840414243

PART NO.

68891688928109368004680036608566083905486889368832693928232168497

560201768494684926854268543

57570406849868491

6848256080087560200882687

DISCRIPTION

4 Piston Pump BodyRoller BearingThrust BearingRace BearingEcc. Shaft Assm.Thrust BearingRace BearingAdaptor Shaft Assm.O-RingRetaining RingAdaptor Piston .210 Dia.Piston .210 DiaPiston SpringBall Stop1/4 Socket Pipe PlugPiston Unloading Assm.Ball Retainer803C-7D Ball BearingIntake SeatTube Assm.R102-10B Ball Bearing

SpringSet ScrewNut-Hex JamSoc Pipe Plug SteelCenter Plate .375Bottom PlateGear Pump .375Shaft-IdlerScreenGuide Tube .375SHCS 1/4-28x1 1/2Spring

Roll PinScrew, Ball StopGasketSHCS 1/4-28x1 3/4Tube ReturnShaft Adp. BackupSpring

PART NO.

6911768360660336647468811661066610868829

56020322689786891568830683406881093950685356604390906660466885191701

689816824268920976416885568849688966885068884689229814868225

81332682268572668255685696951366042

QTY.

111211212111111116112

111311211211

1114121


10/20


11/20

PUMP ASSEMBLIES69122, 18879, 18849

DISCRIPTION

Ball 5mmReturn TubeBackup WasherSpringBearingRetaining RingPIpe PlugExt. Relief SeatExt. Relief ConeValve Relief SpringAdjust ScrewBall 3/16"SpringPiston Block .225Piston Blk. .187 (1887Piston Blk. .290 (1884SHCS 5/16-24x1.75SHCS 5/16-24x5/8Dump PistonSealO-Ring

Lever-DumpPinRetaining RingSOC Set ScrewNut-Self LockingSpringConeSeatBackup WasherO-Ring

QTY.

212131211111111122111

112111111

ITEM

4041424344454647484950515253

53A53B5455565758

59606162636465666768

ITEM

123456789

1011

11A11B12

12A12B1314151617

181920212223242526272829

303132333435363738

PART NO.

6972768569695136604268891688928109368004680036608566083905486889368502689826889969392826876932168497

5602017

68494684926854268543

5757040684986849168482

560800875602008

DISCRIPTION

2 Piston Pump BodyRoller BearingThrust BearingRace BearingEcc. Shaft Assm.Thrust BearingRace BearingAdaptor Shaft Assm.O-RingRetaining RingAdaptor Piston .225 Dia.Adpt. Piston .187 (18879)Adpt. Piston .290 (18849)Piston .225 Dia.Piston .187 Dia. (18879)Piston .290 Dia. (18849)Piston SpringBall Stop1/4 Socket Pipe PlugPiston Unloading Assm.Ball Retainer

803C-7D Ball BearingIntake SeatTube Assm.R102-10B Ball BearingSpringSet ScrewNut-Hex JamSoc Pipe Plug SteelCenter Plate .11Bottom PlateGear PumpShaft-Idler

ScreenGuide TubeScrewPlate-Screen MountScrewSpringRoll Pin 1/8 x 15/16Ball Stop ScrewGasket

PART NO.

6892868360660336647469082661066610868829

56020322689786894568979688206786869980688196834068810939506853566043

909066604668851917016898168242689209764168848688496888368850

689216889468255689278914868225813326822685726

QTY.

111211112111111

11111

511211121121

124111112


12/20


13/20

PUMP ASSEMBLIES18719

DISCRIPTION

Retaining RingPIpe PlugExt. Relief SeatExt. Relief ConeValve Relief SpringAdjust ScrewBall 3/16 303A-16Spring

Dump PistonSealO-Ring 11/16 x .75Dump LeveDump PinRetaining RingScrew Set Soc. RdSelf Locking NutSpringDump ConeInsert SeatBackup Washer

2-008 O-Ring

QTY.

12111111

111112111111

1

ITEM

4546474849505152

535455565758596061626364

65

ITEM

12345678

91011121314151617181920

21222324252627282930313233343536373841424344

PART NO.

6889281093680046800366085660839054868893

6849368497560201768494684926854268543

5757040684986849168482

56080087

5602008

DISCRIPTION

Dump Pump BodyRoller BearingThrust BearingRace BearingEcc. Shaft Assm.Thrust BearingRace BearingAdaptor Shaft Assm.

O-RingRetaining RingAdaptor Pump .187 Dia.2 Piston Pump .187 DiaPiston SpringBall Stop1/4 Socket Pipe PlugPiston Unloading Assm.Ball Retainer803C-7D Ball BearingIntake SeatTube Assm.

R102-10B Ball BearingSpringSet ScrewNut-Hex JamSoc Pipe Plug SteelCenter Plate .11Bottom PlateGear PumpShaft-IdlerScreenGuide TubeScrewPlate-Screen MountScrewSpringRoll Pin 1/8 x 15/16Ball Stop ScrewGasketReturn TubeBackup WasherSpringBearing

PART NO.

6901168360660336647469082661066610868829

560203226897868979689806834068810939506853566043909066604668851

91701689816824268920976416884868849688836885068921688946825568927891486822581332682268572668569

560803276604268891

QTY.

11121111

111111111511

2111211211241111121113


14/20

A A

69312 DUMP VALVE ASSEMBLY

9 3

10

DESCRIPTION

Dump ManifoldBall 5/16Piston-Dump ValveO-RingBackup WasherCompression Spring1/16 SOC Pipe PlugBall Bearing 7/32Compression Spring

Plug SAE #6 PortSOC Pipe Plug 1/8Hex Pipe Plug Asm.

ITEM

123456789

101112

QTY.

111111111

121

PART NO.

6931191701693135602010560801069315976419600668871

681159394969314

45

6

128

11

72

1


15/20

AC

-

+

AC

AC

-

+

AC

A7

9 B

9

B

7

A

6

3

4

1

AC +

AC-

BROWN

GREEN

BLUE

AC

-

+

AC

50V

69493 BREAKER ASSEMBLY 115V MANUAL VALVE

2

10

17

DESCRIPTION

Mounting BracketPlug & Cord Assm.Hose ClampRectifier 25A 50VRelay Sub-Asm 70 SeriesTransformer Sub Assm.Fitting, Cord

Locknut 1/2 inchBridge RectifierTie CableRHMS 10-32 x 5/8Nut 10-24ScrewScrew 1/4-20 x 5/8Hex Nut 1/4-20Wire #14 WhiteButt ConnectorPush On TerminalSpade Terminalwire #14 Black

ITEM

1234567

891011121314151617202123

QTY.

1111111

1122222212112

PART NO.

69256685956923569489695876958668375

85510686236868388032686208596186512938496826266132658886588768261

3

1

23

21

17

16

6

5

20

23

1514

1312

119

114

87


16/20

J

K1

J

K2

ELEC4&ELEC5CONNECTJ TO4

ELEC1CONNECTJ TO 5

K1

93-01

T91S5A22-12

POTTER&BRUMFIELD

240VAC

N.C.10A

N.O.15A

APPLYVOLTAGETO1& 4

115VJUMPER1-2&3-4

1

230VJUMPER2-3

2 3 4 5

&CO,INC.TEMPLETON,KENLY

BOTTOMVIEW

MEXICO

93-01

240VAC

N.C.10A

N.O.15A

T91S5A22-12

POTTER&BRUMFIELD

10876 9

BOTTOMVIEW

MEXICO

K2

+AC

- AC

ELEC4&ELEC5CONNECTJ TO4ELEC1CONNECTJ TO5

240VAC

N.C.

10A

T91S5A22-24

N.O.1

5A

POTTER&BRUMFIELD

APPLYVOLTAGETO1&4

115VJUMPER1-2 &3-4230VJUMPER2-3

1 2 3 4 5

&CO, INC.TEMPLETON, KENLY

BOTTOMVIEW

MEXICO

N.C.

10A

240VAC

T91S5A22-24

POTTER&BRUMFIELD

N.O.1

5A

76 8 9 10

93-01

BOTTOMVIEW

93-01

MEXICO

GREEN

BLUE

BROWN

AC

-

+

AC

69484 MOUNTING BRACKET ASSEMBLY

2

1

8

9

7

DESCRIPTION

Mounting BracketCircuit Board Assm.Bridge RectifierRHMS 10-32 x 5/8Cord FittingLocknut 1/2 inchPlug & Cord Assm.Wire #14 WhitePush-On Terminal

ITEM

123456789

QTY.

111111111

PART NO.

690716897768623880326837585510685956826265888

43

65


17/20

J OG

OFF

ON

GREEN BLACK

WHITE

69380 MOTOR PENDANT

DESCRIPTION

Pendant Body & ReliefJ unction BoxSwitchPendant Cord 20

ITEM

1234

QTY.

1111

PART NO.

69083691506915969381

3

2

1

4


18/20

J OG

OFF

ON

AC

-

+

AC

BA

7

4

1

6

9

3

BROWNGREEN

BLUE

SWITCH

PENDANT

GREEN

BLACK

WHITE

BLACK

GRN/YLWGREEN

GREEN

BLK/GRNRED/BLK

YLW/BLK

69549 BOX ASSEMBLY 30 & 40 SERIES PENDANT

DESCRIPTION

Electrical Box w/ CoverPlug & Cord Assy.Motor PendantCord FittingLocknut 1/2ScrewNut 10 - 24Transformer

ITEM

12345678

QTY.

11122221

PART

NO.6933268595693806937585510859616862068717

9 13

9

13

9

814

15

12

1613

9

9

10

1112

10

10

9 9

1010

9

3 4

1

6

2

7

5

DESCRIPTION

Butt ConnectorWire #14 BlackRelay 12VDC CoilPush-On TerminalWire #14 WhiteWire NutRectifier 25A 50VTerminal Push On

ITEM

910111213141516

QTY.

87193111

PART

NO.6613268261693646588868262680936948969427


19/20

JOG

OFFO

N

BLUEGREEN

BROWN

A7

B9

AC

+

-

AC

1 4

3 6

WIRE AC

+

-

AC

JUMPER

E.M.

GREEN

BLACK

WHITE

SWITCH

PENDANT

37

37

37

42

39

42

25

35

11

3

16

4

14

13

15

43

45

29 3

0

41

28

12

2

8

5

46

17

7

31

32

33

6

44

9

PED

SER

IESDUMP

PUMP

30,40&50SERIESPUMPS

25

31

32

33

29

44 4

5

47


20/20

PED3001

PED3005

PED4005

PED7001Part

Number

69476

1813518719188791884969118691226851169090183886601468000692648749268571860956589165892682596806887305693126887293598689638714569030690316895769004690296970269032683766840369074690766907266238694936948469533695496912569502692346923669159660446837585510881656897765888686236926769380694276896469353844178842969562

PED2001

PED2002

PED2005

PED3002

PED4001

PED4002

PED5005

PED7002

PED7005Item#

12

3

45

678

9101112131415161718

19

25

28

293031

32333536373839414243

444546

Description

RUBBER FOOT

1 GAL SIMPLEX OIL

PUMP ASSEMBLY 1

RESERVOIR

GASKETBREATHER VENT

HEX STL. PIPE PLUGFILLER PLUGSCREW COVER

WASHERSIMPLEX LOGOLABEL, SAFE USEBLANK DECALDUMP VALVE ASSM.VALVE GASKETSHCS 3/8-16x2 1/4ADAPTER ASSM.PIPE PLUGCOVER PLATE

MOTOR

HANDLE

BRK. ASSM.

HEAVY HEX JAM NUTBHSCS 10-24x.5 LGSWITCH

FITTING, CORD L-TIGHTLOCKNUT 1/2SIMPLEX LOGOCIRCUIT BOARDPUSH ON TERMINALRECTIFIER#4 J UMPER WIRE x20MOTOR PENDENTTERMINAL PUSH ONSPACER

1/4-20x1 1/2 SCREWSTAINLESS WASHERHOLE PLUG 7/8

4

11

1

1

1128

2111121

1

1*1

1

1*1

241

1111321122

21

4

21

11

1

11

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1

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241

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21

61

111

12

121221111211

11*1

1

1*1

241

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21

4

2

1

1

1

11

1212

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1

1

1

1

1

1

6

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1

1

1

1

1

4

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1

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1

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2

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1

1

1

1

1

1

6

1

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12

1212

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1

1

1

1

1

6

1

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12

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1111211

1

1

1

4

1

11

1

1128

211112111

1*11

1

*1241

111132112

2221

4

211

1

1

11

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1

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*1241

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6

1

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111132112

2221

4

1

1

1

1

1128

11112111

1

1

1

1

1

PED SERIES DUMP PUMP

Ped Series

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Transcript of Ped Series