Simplex PET SERIES, PAT SERIES, PET2031, PET2042, PET2131 Operating & Maintenance Instructions

HYDRAULIC & MECHANICAL POWER

PET & PAT SERIES

PRO - MAG

TORQUE WRENCH SERIES

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POWER PUMPS

Operating & Maintenance Instructions

1/2

For

and 1

1/2

H.P. Power Pumps

Part Sheet #:
Revised:

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

SIMPLEX DIVISION OF TEMPLETON, KENLY & CO., INC.

2525 Gardner Road Broadview, Illinois 60155 [phone] / Fax [phone]
www.tksimplex.com

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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 agrees with the motor
nameplate.

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

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

4. Oil level should be 1 to 2” from the reservoir plate.

5. Lossen lock nut and back out relief valve to prevent unintended pressure build-up.

6. Never operate the pump with the directional control valve in advance or retract at 10,000 PSI without
wrench movement for more than 1 minute. Leaving the valve in the advance or retract position with
out the wrench moving will overheat the oil.

After Completing the job:

1. Before disconnecting hoses, fitting, etc., first be sure the wrench is retracted and unloaded, than
unplug the power cord.

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 [located in the reservoir]
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 voids the pump warranty.

Working Pressure:

The pump’s maximum working pressure is 10,000 PSI [700 kg/cm ]. Make sure that all hydraulic
equipment such as wrench, hoses, etc. used with this pump are rated at 10,000 PSI operating pressure.

Hydraulic Connections:

Never disconnect or connect any hydraulic hoses or fitting without first unloading the wrench, than unplug
the electrical cord of the pump. Double check the gauge to assure pressure has been released.

When making connections with quick disconnect couplings, make sure the couplings are fully engaged.
Threaded connections such as fittings, gauges, etc. must be securely tightened and 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 be tightened secure &
leak free. Never hold or stand directly in line with any hydraulic connections while pressurizing. Never
grab, touch or in any way come in contact with a hydraulic pressure leak. Escaping oil can penetrate
the skin and a serious injury can result.

SAFETY

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

Electrical Power:

1. Check for proper electrical supply before connecting.

2. This motor may spark. Do not operate in an explosive atmosphere or in the presence of conductive
liquids.

Jacking Safely

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

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 center loading can result in the
ram slipping out and loss of the load.

a. Do not use a power or extension cord that is damaged or has exposed wiring.
b. All single phase motor come equipped with a three prong grounding type plug to fit the
proper grounded type electrical outlet. Do not use a two prong ungrounded extension cord as
the pump’s motor must be grounded.

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

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

INSTRUCTIONS BEFORE USE

Read carefully. Most malfunctions in new equipment are the result of improper operation and/or improper setup
assembly.

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

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

Electrical Connections:

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

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

Hydraulic Connections:

Check hydraulic oil level to prevent possible pump burnout. Open the red plastic fill plug located on the 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 different grade of oil.

Loosen lock nut and back out (turn counter-clockwise ) relief valve to prevent unintended pressure buildup.

Make sure all desired gauge, hose and quick coupler connections are tight and secure before operating. The pumps
pressure ports are located just below the control valve.

Hose Connection:

Couple hoses to pump outlet manifold. “A” port is for advancing and “B” port is for retracting the piston in the
torque wrench. Pump are supplied with the specified coupling halves already connected to the pump ports to
prevent incorrect coupling of hoses to wrench.

Couple hoses to torque wrench. When using SIMPLEX pump and torque wrench combination, Series WH hoses
and couplers are designed so that the pump advance port can only be connected to the wrench advance port, and the
pump retract port can only be connected to the wrench retract port.

OPERATION

Pump Operation:

1. Check all system fittings and connections to be sure they are tight and leak free.

2. Check oil level in reservoir. Oil level should be 1” to 2” from the top of the reservoir plate.

3. Be sure that the pump is “OFF”

4. Be sure the electrical connection is grounded. Check that your power agrees with the motor nameplate.
Plug power cord into outlet.

5. Press “ON” on the pump switch to turn power on. Pressing the “ON” activates the electrical circuit,
but does not turn the motor on. The pump motor is activated by the pendant switch.

6. Pendants supplied with the pumps have a momentary switch. Press momentary switch for
“ADVANCE”. Release “ADVANCE” and torque wrench piston will retract.

NOTE: The electrical motor stays running after pump has stopped. Within 15 seconds of your

last command from the pendant, motor will turn off, preventing heat buildup.

Air removal:

When the wrench is first connected to the pump, To ensure smooth and safe operation, remove air
by cycling wrench several times without load. Cycle unit wrench advances and retracts without
hesitation.

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.

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” switch, and read pressure gauge.

4. While holding the switch, turn relief valve in (clockwise) to increase pressure or out (counter-clokwise)
to decrease maximum pressure. Repeat until correct pressure is obtained.

5. Tighten lock nut on the relief valve to maintain setting.

6. Run pump several times to test this setting.

REFER TO TORQUE WRENCH INSTRUCTIONS FOR WRENCH OPERATING PROCEDURE.

MAINTENANCE

WARNING: THE ELECTRICAL POWER CORD MUST BE DISCONNECTED FROM ELECTRICAL
OUTLETS BEFORE PERFORMING MAINTENANCE OR REPAIR PROCEDURES.

Maintain oil level:

Check hydraulic oil level every 30 hours of operation. Add SIMPLEX oil when necessary. Oil level should be no
more than 2” from top of reservoir plate.

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 condensation inside
the reservoir.
c. Dirty or dusty environments that may contaminate the oil.

Clean oil Filter Screen Once a Year

a. Loosen and remove reservoir plate bolts. Lift pump unit off the reservoir, being careful not to damage
the gasket.
b. Unscrew screen from the bottom of pump unit and clean with nonflammable solvent.
c. Blow dry and reassemble.

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

Flushing the Pump:

If you suspect your pump has been contaminated or discover sludge or other deposits on internal components, you
should toughly flush the pump.

a. Remove the old oil from the reservoir, than toughly clean the reservoir and refill with a clean,
nonflammable flushing oil.
b. Reassemble the pump and motor to the reservoir.
c. Now run the pump in no pressure for 1 or 2 minutes maximum.
d. Unplug the pump and remove the motor and pump assembly again. Now drain the flushing oil and
reclean the inside of the reservoir. (Make sure flushing fluid is also drained from pump assembly).
Refill the reservoir with SIMPLEX hydraulic oil and reassemble the pump.

SECTION V

TROUBLESHOOTING

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

Problem Cause -- Solution

Motor Will Not Start

Be sure power cord is not damaged. Check for
tripped circuit breaker--be sure breaker is of ad­equate size. Have qualified electrician inspect for
loose or faulty wiring. Have motor checked for
defective motor capacitor. Be sure electrical supply
and extension cords are adequate.

Noisy Operation

Pump Oil is Over Heating

Pump Runs but Will Not Pump Oil

1. Air in system.
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 upper
pressure plate. (Leaking at plug).

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

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

2. Check to make sure that externally adjustable
relief valve set properly.
Check internal relief valve.

3. Damaged O-Rings. Take to nearest Simplex
service center for repair.

4. Defective control valve. (Troubleshoot
separately).

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.5 & 1.5 HP ELECTRIC

TORQUE WRENCH PUMP

.5 & 1.5 HP ELECTRIC TORQUE WRENCH PUMP

Item Part

Number

1
2
3
4
5
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49

18135
69159
69284
68722
66012
68231
68608
66014
69264
68000
561604
68551
69496
69285
93943
Y0010260



69074
69076
69727
43384
68672
69353
68571

43166
68963
18718
18852
43364
86095
87492
68957
68376
69371
43407

88363
43362

99921
4100067
CT210

43378
93596
88429
69976
CT211
69529
43370
43369
69972
69365
18970
69236
43365
69234
43366
68964
43355
69018
69479
G7
69526
68607
98250
43408

Description

18135
Switch On/Off
Gage liquid level
Gasket valve
Gasket Motor
Gasket Pump

Gasket Reservoir
Breather Vent

Roll pin
Gasket Pump

Reservoir

Washer

Pipe Plug
Shroud

Manifold Assembly

Spacer

Filler Plug
Elbow 90
Adapter Assembly

Pump Assembly
Screw Cover

Pipe Plug
Motor Electric

Valve Assembly

Gauge Bracket Plate

Screw Manifold & Valve

Nipple
Nipple

Tube Elec T-Wrench
Screw Motor
Washer

Pipe Connecto

Female Coupler

MountingBracket

Adv. Pendant

Elbow 90 Strt.
BHCS 10-24X .25

Hex Nut
SCR Self Form

Screw 1/4 - 20
Motor Cover
Rubber Foot
700 Bar Gage
Cover Plate (All Others)
Cover Plate (1 Gal. Only)

Screw

Pres Gauge W / Flange

PET2031

PET2042

PET2131

PET2141

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PET2841

PET7042

PET7142

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PET7342

PET7842

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