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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
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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-
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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-
!
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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-
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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-
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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-
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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-
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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
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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
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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
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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
7/27/2019 Ped Series
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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
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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
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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
7/27/2019 Ped Series
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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
7/27/2019 Ped Series
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
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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
1212
21111211
11*1
1
1*1
241
1111321122
21
61
111
12
121221111211
11*1
1
1*1
241
1111321122
21
4
2
1
1
1
11
1212
1111211
1
1
1
1
1
1
6
1
111
12
1212
1111211
1
1
1
1
1
4
1
1
1
1
1128
11112111
1
1
1
1
1
4
2
1
1
11
1212
1111211
1
1
1
1
1
1
6
1
111
12
1212
1111211
1
1
1
1
1
6
1
111
12
1212
1111211
1
1
1
4
1
11
1
1128
211112111
1*11
1
*1241
111132112
2221
4
211
1
1
11
1212
21111211
1
1*11
1
*1241
111132112
2221
6
1
111
12
121221111211
1
1*1
1
1
*1241
111132112
2221
4
1
1
1
1
1128
11112111
1
1
1
1
1
PED SERIES DUMP PUMP