G5 AUTOCYCLE
TORQUE PUMP
Reference # - TD069
Rev. - A
Date - 0810
2525 GARDNER ROAD, BROADVIEW, IL 60155
1.800.323.9114 • Outside U.S. 1.708.865.1500
www.tksimplex.com
- Note -
SIMPLEX has taken every care in preparing this Operational Manual that is intended as a technical guideline only.
SIMPLEX accepts no liability in relation to any use or reliance made of any information in this Operational Manual.
All information, illustrations and specications in this Operational Manual are based on the latest information
available at the time of publication. The right is reserved to make changes at any time without notice.
Equipment operators and installers shall be responsible for ensuring that a safe working environment and safe
systems of work are in place before operating the equipment.
©2010 SIMPLEX
CONTENTS
Receiving Instructions and Warranty Statement .........................................................................................................2
Safe and Correct Use ...................................................................................................................................................3
Technical Specifications ...............................................................................................................................................4
Working Pressure .........................................................................................................................................................4
Install Vent Plug ............................................................................................................................................................4
Adding Oil .....................................................................................................................................................................4
Electrical .......................................................................................................................................................................4
Connecting Hydraulic Tools ..........................................................................................................................................4
Starting Pump the First Time .................................................................................................................................... 4-5
Pump Mounting ............................................................................................................................................................5
Control Valves ...............................................................................................................................................................5
Power Control Switches ...............................................................................................................................................5
Pressure Torque Setting ...............................................................................................................................................6
Diagnostic Mode ..........................................................................................................................................................6
After Completing the Job .............................................................................................................................................6
Periodic Maintenence ...................................................................................................................................................6
Maintain Oil Level .........................................................................................................................................................7
Clean Oil Intake Screen ................................................................................................................................................7
Flushing the Pump .......................................................................................................................................................7
PENDANT CONTROL SECTION
Pendant Overview ........................................................................................................................................................8
Pendant Startup ...........................................................................................................................................................9
Main Menu ..................................................................................................................................................................10
Unit Settings ...............................................................................................................................................................10
Manual Mode ..............................................................................................................................................................10
Auto Cycle Mode...................................... ..................................................................................................................11
History Menu ..............................................................................................................................................................11
Troubleshooting ..........................................................................................................................................................12
TO RETRIEVE TECHNICAL PART SHEET DOCUMENTATION, GO TO: WWW.TKSIMPLEX.COM
G5 Torque Pump
••• 2 •••
IMPORTANT - READ CAREFULLY
This manual contains important information for the correct installation, operation and maintenance of this
equipment. All persons involved in the installation, operation and maintenance of this equipment must be
thoroughly familiar with the contents of this manual. To safeguard against the possibility of personal injury or
property damage, follow the recommendations and instructions of this manual. Keep this manual for reference.
WARRANTY STATEMENT
SIMPLEX products are warranted to be free of defects in materials and workmanship under normal use for
as long as the original purchaser owns them, subject to the guidelines and limitations listed. This warranty does
not cover: normal wear & tear, cosmetic items, abuse, overloading, alterations, improper fluid, or use in a
manner for which they are not intended. If the customer believes a product is defective, the product must be
delivered, or shipped freight prepaid, to the nearest SIMPLEX Authorized Service Center for evaluation and
repair.
1.0 RECEIVING INSTRUCTIONS
Important! Make sure to inspect all of the components for shipping damage. If damage is found, notify carrier at
once. Shipping damage will not be covered by warranty. The carrier is responsible for all loss associated with
shipping damage.
••• 3 •••
2.0 SAFETY
Make sure to read the instructions, warnings and precautions carefully. Follow any recommended safety precautions
to avoid personal injury or damage to the unit. Simplex cannot be responsible for any damage or injury from unsafe
use, lack of maintenance or incorrect operation. In the event any questions or concerns arise, contact SIMPLEX or a
local Distributor for clarication.
The pump’s maximum working pressure is 10,000 PSI (700kg/cm2). Make
sure that all hydraulic equipment such as tools, hoses, etc. used with this
pump are rated at 10,000 PSI (700kg/cm2) operating pressure.
If you have never been trained on high-pressure hydraulic safety, consult
your distributor or service center for a free Simplex Hydraulic Safety Course.
Failure to comply with the following cautions and warnings could cause equipment damage, property damage or
personal injury.
DANGER is only used when your action or lack of action may cause serious injury or even death.
WARNING indicates a potential danger that requires correct procedures or practices to avoid personal injury.
CAUTION is used to indicate correct operating or maintenance procedures and practices to prevent damage
to, or destruction of equipment, or other property.
WARNING: Wear proper personal protective gear when operating hydraulic equipment.
DANGER: To avoid personal injury, keep hands and feet away from tool and work-piece during operation.
WARNING: Do not exceed equipment ratings. Overloading causes equipment failure and possible personal injury.
The tools are designed for a maximum pressure of 10,000 PSI (700kg/cm2). Do not connect a tool to a pump with a
higher pressure rating. Never set the relief valve to a higher pressure than the maximum rated pressure of the pump.
Higher settings may result in equipment damage and/or personal injury.
WARNING: The system operating pressure must not exceed the pressure rating of the lowest rated component in
the system. Install pressure gauges in the system to monitor operating pressure. It is your window to what is
happening in the system.
CAUTION: Avoid damaging hydraulic hose. Avoid sharp bends and kinks when routing hydraulic hoses. Using a
bent or kinked hose will cause severe back-pressure. Sharp bends and kinks will internally damage the hose, leading
to premature hose failure.
Do not drop heavy objects on hose. A sharp impact may cause internal damage to hose wire strands. Applying
pressure to a damaged hose may cause it to rupture.
IMPORTANT: Do not lift hydraulic equipment by the hose or swivel couplers. Use the carrying handle or other means
of safe transport.
CAUTION: Keep hydraulic equipment away from ames and heat. Excessive heat will soften seals, resulting in uid
leaks. Heat also weakens hose materials. For optimum performance do not expose equipment to temperatures of
65° C (170° F) or higher. Protect hoses and tools from weld spatter.
DANGER: Do not handle pressurized hoses. Escaping oil under pressure can penetrate the skin, causing serious
injury. If oil is injected under the skin, see a doctor immediately.
DANGER: Only use hydraulic tools in a coupled system. Never use a tool with unconnected couplers. If the tool becomes severely overloaded, components can fail catastrophically causing severe personal injury or death.
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••• 4 •••
3.0 TECHNICAL SPECIFICATIONS
G5 Electric Torque Wrench
Voltage 115V 230V
Operating Pressure 10,000 PSI (700kg/cm2)
Electrical Power Source 20 Amps 115V Grounded 50/60 Hz 10 Amps 230V Grounded 50/60 Hz
Motor Rating 1.125 Hp Single Phase
Flow Rate 575 cu. in./ min. @ 1,100 psi, 55 cu. in / min. @ 10,000 psi
Maximum Operating
Temperature
18 Amps @ 10,000 psi (700kg/cm2)
170F - (65C)
1.125 Hp Single Phase
10 Amps @ 10,000 psi (700kg/cm2)
4.0 WORKING PRESSURE
The pump’s maximum working pressure is 10,000 PSI (700kg/cm2). Make sure that all hydraulic equipment such as
rams, hoses, etc. used with this pump are rated at 10,000 PSI (700kg/cm2) operating pressure.
4.1 INSTALL VENT PLUG
Remove SHIPPING PLUG (A) and install VENT PLUG (B) into ll plug.
4.2 ADDING OIL
Remove OIL FILLER CAP (C) and add SIMPLEX Hydraulic Oil into reservoir.
B
A
C
Oil level should not exceed 1” from the reservoir cover.
*As a “rule of thumb” oil should be visual in site window when the unit is
powered down and all connected tools are retracted.
4.4 ELECTRICAL
Check for proper electrical supply before connecting. Be sure the electrical connection is grounded. Check that your
power supply agrees with the motor nameplate and/or Simplex model decal.
NOTE: MOTOR MAY SPARK. DO NOT OPERATE IN AN EXPLOSIVE ATMOSPHERE OR IN THE PRESENCE OF
CONDUCTIVE LIQUIDS.
1. Do not use a power or extension cord that is damaged or has exposed wires.
2. All single phase motors come equipped with a three prong grounding type plug to t the proper grounded
type electrical outlet. Do not use a two prong ungrounded extension cord as the pump’s motor must be
grounded.
4.5 CONNECTING HYDRAULIC TOOLS
Use only tools, hoses and accessories rated at 10,000 PSI (700kg/cm2). When making connections with quick
disconnect couplings, make sure the couplings are fully engaged. Threaded connections such as ttings, gauges,
etc. must be securely tightened and leak free. Use 1.5 wraps of Teon tape (or suitable thread sealant) on all threads,
leaving the rst complete thread free of tape to ensure no foreign matter enters the hydraulic circuit.
4.6 STARTING THE PUMP FOR THE FIRST TIME
1. Locate the “ON” button on the pendant and Depress. Check for any leaks, repair as needed.
2. Depress “ADV” button to advance tool and release to retract tool. Look for movement in tool,
check for any leaks, repair as needed.
••• 5 •••
A
CAUTION: Never operate the pump without tool movement for more than 1 minute. Leaving the valve in the advance
or retract position without the tool’s piston rod moving will overheat the oil.
CAUTION: Never disconnect or connect any hydraulic hoses or ttings without rst unloading the tool, then unplug
the electrical cord of the pump. Open manual relief valve to assure that the system has been depressurized. View
the gauge reading and double check the gauge to assure pressure has been released.
4.7 PUMP MOUNTING
Refer to the chart for mounting dimensions to secure the pump to a xed surface.
1.5 gal.(6L) 2.5 gal.(10L) 5 gal. (20L)
A
B
C
D
E
F
15.13 17 19.6
1.68 2.75 4.69
3.57 4.37 5.03
1.43 1.93 2.93
8.75 9.75 11.75
1/4-20unc
(4 places)
1/4-20unc
(4 places)
1/4-20unc
(4 places)
B
D
F
E
C
5.0 CONTROL VALVES
2-Postion – 4 Way Solenoid Valve for Hydraulic Torque Wrenches.
• To Advance......depress the Advance button.
• To Retract.........release advance switch to Retract Tool.
5.1 POWER CONTROL SWITCHES
Remote pendant.
Congured with motor control pendant:
ADVANCE = Press and hold button to turn motor on.
Energizes ADV. Coil.
ON = Press button to turn motor on.
OFF = Press button to turn motor off.
NOTE: In the event multiple buttons are depressed for longer than 5 seconds,
the unit is programmed to shut down. To restart, you will need to depress the
motor “ON” to continue, or unplug / re-plug the unit into power supply, then
depress the motor “ON” to continue.
2 Position - 4 Way Solenoid
Motor/Valve Control Pendant
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••• 6 •••
5.2 PRESSURE TORQUE SETTING
WARNING: Make these adjustments BEFORE putting torque wrench on nut or bolt head. The pump pressure
setting may be above the pressure needed to provide the required torque for your application. Exceeding required
torque will cause equipment damage and may lead to serious personal injury.
AdjustingKnob
1. See torque wrench instructions for amount of pressure required
to produce desired torque.
2. Loosen lock nut and back out relief valve to prevent unintended
pressure build up.
3. Turn pump on. Press and hold the “ADVANCE” button, and read
pressure on the digital display on the pendant. (Manual Mode)
LockNut
4. While holding the button, turn relief valve in (clockwise)
to increase pressure or out (counter-clockwise) to decrease maximum
pressure.
Repeat until correct pressure is obtained.
5. Tighten lock nut on the relief valve to maintain setting.
ValveAssembly
6. Run pump several times to test this setting before setting tool on the nut.
DIAGNOSTIC MODE
• Highlight & Press “enter” to select DIAGNOSTIC MODE.
❶
• DISPLAY TEST - Highlight & press “enter” to select DISPLAY TEST. Press
“enter” again to end the test.
❷
Press “left” arrow button to return to MAIN MENU.
• KEYPAD TEST - Highlight & press “enter” to select KEYPAD TEST. Press
any button to test. Press “menu” to exit.
❸
• CIRCUITRY TEST - Highlight & press “enter” to select CIRCUITRY TEST. If
circuit diagnostic is OK, press any key to exit.
➍
Press “left” arrow key to return to MAIN MENU.
5.3 AFTER COMPLETING THE JOB
Before disconnecting hoses, ttings, etc., rst be sure the tool is unloaded and
retracted, then unplug the power cord. The pump is designed to cycle valve
upon power down “off.”
6.0 PERIODIC MAINTENANCE
Completely change the hydraulic oil and clean the intake screen and magnet
(located in the reservoir) twice a year. If equipped, change the external oil lter
twice a year (Use Simplex oil only, Model # AO1, 1 gallon). Change the oil
more frequently when used in extremely dusty areas or when the oil has been
overheated. Using oil other than Simplex Brand may void the pump’s warranty.
DIAGNOSTIC MODE
DISPLAY TEST
❷☞
KEYPAD TEST
❸☞
CIRCUITRY TEST
➍☞
❶☞
Power Control Center
ADVANCE
ON
OFF
MENU
ENTER
The following conditions require more frequent oil changes.
• Rigorous duty, where oil temperature may reach 150˚ F.
• High humidity environment and extreme changes in temperature that can result in condensation inside the
reservoir.
• Dirty or dusty environments that may contaminate the oil.
• Frequent connection and disconnection of hydraulic hoses and components.
WARNING: The electrical power cord must be disconnected from electrical outlets before performing maintenance
or repair procedures.
••• 7 •••
6.1 MAINTAIN OIL LEVEL
Check hydraulic oil level every 30 hours of operation (sight gauge should be completely covered in oil when all tools
are retracted. Add Simplex oil (Model # AO1 – 1 gallon) when necessary. Oil level should be no more than 1” from top
of reservoir plate – with tools retracted and motor off.
6.2 CLEAN OIL INTAKE SCREEN ONCE A YEAR
Loosen and remove reservoir plate bolts. Lift pump unit off the reservoir, being careful not to damage the gasket.
Applies to the 1.5, 2 and 2.5 gallon reservoirs:
Remove the 5 Allen socket head cap screws securing the screen to the rst stage gear pump. Care should be taken
not to remove the center plate and gears. Remove and clean with non-amable solvent and blow dry clean. Reinstall
in reverse order and torque bolts to 75 inch pounds. Keep the motor and pump as clean as possible.
6.3 FLUSH THE PUMP
If you suspect your pump has been contaminated or discover
sludge or other deposits on internal components, you should
thoroughly ush the pump. Remove the old oil from the reservoir,
then thoroughly clean the reservoir and rell with a clean,
nonammable ushing oil. Reassemble the pump and motor to
the reservoir.
Run the pump in no load condition for 1 or 2 minutes maximum.
Unplug the pump and remove the motor and pump assembly
again. Now drain the ushing oil and re-clean the inside of the
reservoir. (Make sure ushing uid is also drained from pump
assembly). Rell the reservoir with Simplex hydraulic oil and
reassemble the pump.
Oil Fill (1.5 - 2.5 Gal. Models)
Sight Gauge
Drain Plug (1.5 - 10 Gal.)
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PENDANT OVERVIEW
LCD DISPLAY
••• 8 •••
Power Control Center
“ADVANCE” BUTTON”
DEPRESSING BUTTON ACTIVATES
MOTOR “ON” AND ADVANCES TOOL.
“ON” BUTTON”
DEPRESSING BUTTON ACTIVATES
MOTOR “ON”
“OFF” BUTTON”
DEPRESSING BUTTON TURNS
MOTOR “OFF” AND CYCLES VALVE TO
RELIEVE PRESSURE TRAP.
MENU / ENTER / ARROW BUTTONS
EXECUTES A COMMAND
• UP BUTTON MOVES CURSOR UPWARD
CHANGES VALUE
• DOWN BUTTON MOVES BUTTON DOWNWARD
CHANGES VALUE
ADVANCE
ON
OFF
MENU
ENTER
• LEFT BUTTON MOVES CURSOR
LEFT OR RETURNS BACK
• RIGHT BUTTON MOVES CURSOR
RIGHT OR CHANGES VALUE
NOTE: WHEN IN MANUAL MODE PRESSING THE “UP” ARROW DARKENS CONTRAST
PRESSING THE “DOWN” ARROW LIGHTENS CONTRAST
••• 9 •••
PERFORMING SYSTEM
CHECK
OK
SOFTWARE VER. X.X
TORQUE WRENCH
PENDANT - START UP
Upon “Power Up”, unit will perform system check. If critical fault(s) are detected, unit will not start and fault(s) will be
displayed here (Fig.1). Warnings will not prevent the unit from starting.
The “Manual Mode” screen will display after the system check is complete and will default to “Manual Mode”
(Fig. 2). Screen displays pressure in selected units (PSI, Bar, MPa) and indicates the motor status.
Power Control Center
ADVANCE
ON
OFF
MENU
ENTER
FIG. 1
FIG. 2
Power Control Center
ADVANCE
ON
OFF
MENU
ENTER
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••• 10 •••
MAIN MENU - FIG. 3
To enter the “main menu”, depress “MENU/ENTER” button. By pressing the “up” or
“down” arrow buttons, sub-menus can be highlighted. Once the preferred sub-menu is high-
lighted, press the “MENU/ENTER” button to go into that sub-menu mode.
To return to the “main menu” press the “left arrow button”.
❶
FIG. 3
Power Control Center
UNIT SETTINGS - FIG. 4
• Highlight & press “enter” to select UNIT SETTINGS.
• MODE - PRESSURE or TORQUE is chosen by highlighting & pressing “enter” button.
To return to the “main menu” press the “left arrow button”.
• UNITS - In PRESSURE mode, units (kg/cm2 , PSI, Bar and KPA) are displayed by
highlighting & pressing the “enter” button until desired form of measurement is displayed.
To return to the “main menu” press the “left arrow button”.
• SAVE the data by pressing the “down” arrow button to “save” mode and press “enter”.
To return to the “main menu” press the “left arrow button”.
• UNITS - In TORQUE mode, “units” (lb-ft, NM, KPM,) are displayed by highlighting &
pressing the “enter” button until desired form of measurement is displayed.
To return to the “main menu” press the “left arrow button”.
• SAVE the data by pressing the “down” arrow button to “save” mode and press “enter”.
To return to the “main menu” press the “left arrow button”.
• TOOL - Highlight & press “enter” and use the “arrow” buttons until the desired TOOL is
selected. If the TOOL being used is not a SIMPLEX TOOL, select “other”. If no TOOL is be-
ing used, select “none”.
➍
To return to the “main menu” press the “left arrow button”.
• SAVE the data by pressing the “down” arrow button to “save” mode and press “enter”.
To return to the “main menu” press the “left arrow button”.
❶
❶
❸
MANUAL MODE - FIG. 5
➎
➎
➎
❸
❶☞
❷☞
❸☞
➍☞
➎☞
❶☞
ADVANCE
ON
OFF
MENU
ENTER
FIG. 4
Power Control Center
ADVANCE
ON
OFF
MENU
ENTER
• Highlight & press “enter” to select MANUAL MODE.
❶
• To operate pump, press the “ADVANCE” button to turn pump motor on and
advance the tool.
❷
To return to the “main menu” press the “menu/enter button”.
❷☞
❶☞
FIG. 5
Power Control Center
ADVANCE
ON
OFF
MENU
ENTER
AUTO-CYCLE MODE
••• 11 •••
• Highlight & press “enter” to select AUTO-CYCLE mode.
❶
• TOOL - Press “enter” and use the “arrow” buttons until the desired TOOL is selected. If the TOOL being used is not a SIMPLEX TOOL, select “other”. If no TOOL is
being used, select “none”.
❷
To return to the “main menu” press the “left arrow button”.
• MODE - PRESSURE or TORQUE is chosen by highlighting & pressing
“enter” button. If TORQUE is selected, you must select a “tool” or “other” and
“enter” data.
❸
To return to the “main menu” press the “left arrow button”.
• TARGET - Highlight & press “enter” to select TARGET and use the “up” and
“down” keys to raise or lower the TARGET Pressure. Use the “right and “left” arrow
keys to select the desired digit column.
➍
To return to the “main menu” press the “left arrow button”.
• RUN - Highlight & press arrow key “down” and press “select” to run the
AUTO-CYCLE mode. Unit will AUTO-CYCLE until the target goal is achieved. To
interrupt during a cycle, depress any button.
To return to the “main menu” press the “left arrow button”.
HISTORY MENU
• Highlight & press “enter” to select HISTORY MENU.
❶
AUTO CYCLE MODE
TOOL
❷☞
MODE
❸☞
TARGET
➍☞
❶☞
Power Control Center
ADVANCE
ON
OFF
MENU
ENTER
• MOTOR RUN TIME - Highlight & press “enter” to view the total number of HOURS
and CYCLES for the desired selection.
❷
To return to the “main menu” press the “left arrow button”.
• WARNING HOURS - Highlight & press “enter” to view the WARNING TIME
❸
total.
To return to the “main menu” press the “left arrow button”.
• FAULT TIMES - Highlight & press”enter” to view the FAULT TIMES TOTAL.
To return to the “main menu” press the “left arrow button”.
➍
HISTORY MENU
MOTOR RUN TIME
❷☞
WARNING HOURS
❸☞
FAULT TIMES
➍☞
❶☞
Power Control Center
ADVANCE
ON
OFF
MENU
ENTER
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••• 12 •••
7.0 TROUBLESHOOTING
PROBLEM CAUSE-SOLUTION
Sporadic Tool Action: • Air in the hydraulic system. Bleed the hydraulic circuit.
• Check reservoir oil level.
Motor Will Not Start: • Be sure power cord is not damaged.
• Check for tripped circuit breaker; be sure breaker is of adequate
size.
• Have motor checked for proper operation.
• Have qualied electrician inspect for loose or faulty wiring or switch.
• Check fuse on electical bracket.
Noisy Operation: • Air in system.
• Be sure the oil reservoir is lled to normal level.
• Check all points where air might leak into system.
• Clogged or blocked intake screen.
Pump Oil is Over Heating: • Inspect for high pressure leakage at the pump (leaking at plug or
relief valve).
• Oil level is low. Fill reservoir to normal level, or retrot the pump with
larger reservoir or heat exchanger.
Pump Runs But Will Not Pump Oil: • Pump is not primed. Run pump a few minutes tipping from side to
side.
• Inspect to make sure that external adjustable relief valve is set
properly.
• Defective control valve, take to nearest Simplex Authorized Service
Center for repair.
• Incorrect motor rotation, take to nearest Simplex Authorized Service
Center for repair.
• Check to make sure the intake screen is not clogged. Clean if
needed.
• Check oil reservoir is low. Fill as needed.
• Oil viscosity is too high. Replace with SIMPLEX oil.
SIMPLEX PRODUCTS ARE WARRANTED TO BE FREE OF DEFECTS IN MATERIALS AND WORKMANSHIP UNDER NORMAL USE FOR AS LONG AS THE
ORIGINAL PURCHASER OWNS THEM, SUBJECT TO THE GUIDELINES AND LIMITATIONS LISTED. THIS WARRANTY DOES NOT COVER : NORMAL WEAR
AND TEAR, COSMETIC ITEMS, ABUSE, OVERLOADING, ALTERATIONS. IMPROPER FLUID, OR USE IN A MANNER FOR WHICH THEY ARE NOT INTENDED.
IF THE CUSTOMER BELIEVES A PRODUCT IS DEFECTIVE, THE PRODUCT MUST BE DELIVERED, OR SHIPPED FREIGHT PREPAID, TO THE NEAREST SIMPLEX AUTHORIZED SERVICE CENTER FOR EVALUATION AND REPAIR.
2525 GARDNER ROAD, BROADVIEW, IL 60155
1.800.323.9114 • Outside U.S. 1.708.865.1500
www.tksimplex.com
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