The Simplex ES - Series

Operating & Maintenance Instructions

• Capacity 100 Tons• Height Closed/Ext. 25 1/2" / 40 1/2"• Weight 458 lbs.

The world's most complete line of industrial, hydraulic andmechanical lifting and load-holding equipment.SIMPLEX DIVISION OF TEMPLETON, KENLY & CO., INC.2525 Gardner Road • Broadview, Illinois 60155 • (708) 865-1500 / Fax (708) 865-0894

Revised 5-94

•More rapid advance & Retract•Double acting Hydraulic cylinder (Heavy Duty Design) with 4-way valve & check valve•Lighter - Aluminum housing•More efficient - Operates despite starved air conditions

•Quieter - 81 Decibels•Gage port included•Serrated load cap & base•Larger wheels (semi-pneumatic)•Rocker plate•Less maintenance required - easy to repair

FEATURES AND BENEFITS

Available With Air, Gasoline or Electric Motor

100 TONPOW'R - RISER

CONTENTS

Maintenance at a Glance Page 2

Basic Assembly Instruction Fig. 1 Page 3

Basic Operating Instructions Fig. 2A & 2B Page 4 & 5

Part Sheet - Basic Assembly Fig. 3 Page 6 & 7

Part Sheet - Basic Sub-Assembly Fig. 4 Page 8 & 9

Part Sheet - Pump & Motor Assembly Fig. 5A & 5D Page 10 & 12

Part Sheet - Stand. Cylinder Assembly Fig. 6 Page 13

Part Sheet - Control Valve Assembly Fig. 7 & 7A Page 14 & 15

Part Sheet - Handle Support Fig. 8 Page 16

Part Sheet - Air Motor Fig. 9 Page 17

Part Sheet - Filter Lubricator Fig. 10 Page 18

Part Sheet - 44" Min. Basic Assembly Fig. 11 Page 19 & 20

Part Sheet - 44" Min. Cylinder Assembly Fig. 12 Page 21

Maintenance:A. Oil Page 22B. Pump Assembly Page 22 & 23C. Air Motor Page 23D. Disassembly Procedure Page 24

Troubleshooting Page 25

1

POW'R-RISER MAINTENANCE & OPERATING TIPS

1. IMPORTANT: You must move the directional control valve handle to neutral (centerposition) or close the air shut off valve when the piston rod reaches the end of its travel(up or down). Allowing the jack to build full pressure with the rod fully extended orretracted quickly heats and deteriorates the oil.

2. Inspect the oil once a week.

❍ Visual -- look for water or solid contaminants. Compare color to new oil. "Milky" oil must be compared.

❍ Touch -- compare used oil to new oil for grittiness by rubbing between your fingers. Gritty oil must be changed.

3. Normally change the hydraulic oil after every 50 hours of operation or every 90 days,whichever occurs first.

4. Hydraulic Oil:• Keep clean• Don't mix• Use only Simplex #9

5. Try to protect the piston rod from being struck with tools or other objects. Fully retractthe rod when not in use.

6. Store in a clean, dry area. (Keep the hydraulic oil clean).

7. Adjust the lubrication assembly (#86282, Fig. 10) to 1 or 2 drops a minute, maximum.The lubricator is filled the an anti-freeze fluid (#18243 - pint), and if needed, should onlybe replaced with that fluid. Suitable substitute is Killfrost.

8. Jack must be perpendicular to the load. Jacking on an angle can result in the jackslipping out and loss of the load (see Fig. 3, Page 3).

2

1. ASSEMBLY INSTRUCTIONS

The Pow'r-Riser was shipped with the handle assembly (#85465) and the Breather (#30 -fig. 4 removed for ease of packaging. Remove the pipe plug located on the top reservoircasting by the motor mounting plate and thread in the breather (see fig. 4 - #30 for loca-tion).

Figure 1

#85464Handle Support Assembly

#85475Roll Pin

Hole "B"

Flush-roll pin assembled position

Hole "A"

#85465Handle Assembly

HANDLE ASSEMBLY

1. Slide handle assembly.(#85465) into handle supportassembly. (#85465) untilHole "A" lines up with Hole"B".

2. Drive roll pin (#85475) intoHole "B" until it is flush withhandle support assembly(#85464).

The Pow'r-Riser is now ready foroperation.

3

TO RAISE LOAD: (Refer to Figures 2A and 2B)

1. Pull out knob (item 1) and swing handle assembly (Item 2) up.

2. Place foot on pad (Item 3) and pull out and down on handle assembly (Item 2). Pow'r-Risercan now be pushed or pulled to work area. If it ever becomes necessary to move the Pow'r-Riser by truck, it should be picked up under base (Item 9) or by means of eye bolt (Item 11).Never attempt to pick up jack by handle assembly (Item 2) or swing handles.

3. At the work station, the jack should be positioned on a solid foundation (wooden blocks be-tween the load and the jack and under the base of the jack are preferred).

NOTE: The jack must be perpendicular to the load; jacking on an angle can result in the jack slipping out and loss of the load.

4. Once the jack has been placed on support blocks, final positioning can be accomplished withswing down handles (Item 4A & 4B). Handle assembly (Item 2) should be swung down out ofthe way prior to jacking.

5. Connect air supply to air valve (Item 5). (1/2 - 14 NPT)

6. Open air valve (Item 5) and move the directional control valve handle (Item 7) to the advance position.

7. Never allow the jack to run without ram movement for more than 1 minute without movingdirectional control valve to neutral. Letting the jack run with the valve in the advance or retractposition after the piston rod has fully extended will overheat the jack.

8. When load has reached the proper level, place the control valve handle in neutral (center)position.

CAUTION: If using Pow'r-Riser in combination with any other jack, special care must be takento keep the load level, as the Pow'r-Riser will run at a faster rate than any other similar jack onthe market. Leveling should be accomplished by throttling the air valve.

9. Place solid stands under the load.

10. Place directional control valve handle (Item 7) in the lower position (see figure 2A) loweringload onto stands. Place directional control valve handle in neutral position. Close air valve(Item 5).

TO LOWER LOAD:

11. Open air valve (Item 5).

12. Move directional control valve handle to raise position (see Figure 2A).

13. When load clears stands, place directional control valve handle in neutral position. Removestands.

14. Move valve handle (Item 7) to the lower position.

15. When piston has fully retracted, place directional control valve handle in neutral (center) posi-tion and close the air valve.

4

AIR

MO

TO

R P

OW

ER

ED

PO

W'R

-RIS

ER

Fig

ure

2B

Fig

ure

2A

Rai

seLo

wer

10

9

2

7

3

5

1

11

1

4A4B

6

S I M P L E X

5

POW'R-RISER BASIC ASSEMBLY

ITEM

123456789101112131415161718

QTY.

1111

11211111411111

CONTROL #

18333182338585188070181398782613299015570188074880678782787829935828546918243881118602788120

DESCRIPTION

Load CapFilter/Lubricator AssemblyAir Shut Off ValveAir Pump AssemblyHydraulic Oil/5 GallonModel DecalPow'r-Riser Basic AssemblyHand GripValve AssemblyTube AssemblyElbowDrain LineSoc. Hd. Cap ScrewGasketAnti-Freeze Lub.Caution DecalControl Valve PlateES Pow'r-Riser Decal

USE FIG. 3

SPECIFICATIONS:

1. Capacity: 100 U.S. Tons @ 9,239 PSI2. Stroke: 15 Inches3. Air Pr./Air Vol. Req'd.: 100 PSI/105 SCFM4. Speed of Piston Travel Under Full Load:

100 PSI: 3 3/4 in./min. 90 PSI: 3 1/4 in./min. 80 PSI: 3 in./min.

5. Reservoir Capacity: 5 Gallons

6

POW'R-RISER BASIC ASSEMBLY

SIMPLEX

FIGURE 3

1

11

16

8

10

5

6

18

7

23

4

9

13

17

14

1226

25.5 Min. 40.5 Max.

Rear Screen Must berelocated and as-sembled together alongwith the front. Screen atthe assembly beforetest.

25.5

OilLevel

1 1/2" to 2"

7

ITEM

123456789101112131415161718192021222324252627282930313233343536373839404142

QTY.

1111213212111111122221462224211163011112111

CONTROL #

8805385464854658545185457877748615585468840278547088057*8797301*88060*88068*854738635318107*18109*9395056024419530685475935948585593866854779393093943937826800085853854558600686007550248622518117*848538806688059*8805818970*

DESCRIPTION

Cylinder AssemblySupport AssemblyHandle AssemblyHousing ReservoirHandleRingSet ScrewShaftRelief ValveTire & WheelNippleOver Center ValveHose AssemblyHose AssemblyPipe NipplePipe NippleElbowStreet ElbowSocket Pipe PlugO-RingRoll PinRoll PinSoc. Hd. Cap ScrewHex CapHex. Slotted NutHex. Jam NutPlate WasherLock WasherCotter PinBreather Vent & FilterNylon WasherBaseHex. Head ScrewWasherSafety Valve Enclosure KitEye BoltSwivel FittingCaution DecalSpacerElbowNippleElbow

* Included in O.C. Valve Kit #18060 that will completely interchange with older valves.

POW'R-RISER SUB-ASSEMBLY

USE FIG. 4

8

30

38 9 35

19

29

8

25

27

26

39

10

15

28 23 36

2

7 6

21

20

5

4

11

17

1

14

12 24

20 31

32

33 34 16 18 37 40 19

41

40 41 42

13

10

18 3

22

11 18

12

42

41

40 37 13

14

17

View A-A

Fill Plug

Torque to Max. 250 ft.lb.

.03 Gap (Typ)wheels must havefree rotation

+00 -.01

4.68(Typ.)

+.06 -00

25.5(Ref.)

24.75

26.2Torque to150 in. lbs.

Drain

POW'R-RISER SUB-ASSEMBLY

USE FIG. 4

9

ITEM

123456789101112131415161718192021222324252627282930313233

QTY.

111114123111111133331612211114111

CONTROL #

8550166012880698783168090*84692880736588156020126605366106661086807366473660336647456020106806666231*560211068192*680566808465879974858847066122680646805768058181011810918125

DESCRIPTION

Motor AirGasketCover PlateGasket-High PressureH.P. Plate AssemblyS.H.C.S.Adapter ValveBack Up WasherO-RingTube High FlowBearing ThrustRace BearingEccentric AssemblyRace BearingBearing ThrustRace BearingO-RingBack-Up WasherPiston Block AssemblyO-RingLow Pressure PlateS.H.C.S.Gear PumpH.H.C.S.Lock WasherSuction StrainerKeyTube AssemblySeal Plate AssemblyB.H.C. ScrewNippleSt. ElbowReducer Bushing

* For details, see figures 5B, 5C, & 5D.

PUMP & MOTOR MOUNTING ASSEMBLY#88070

USE FIG.5A

10

30

29

7

9

8 3

4 5

18

17

19

10

9

25

24

31

21

11

USE FIG. 5A

View C-C

Position hi-flow cartridge as required toassemble lubricator. Lubricator assemblyshown in final location

PUMP & MOTOR MOUNTING ASSEMBLY

View A-A Scale 1/2

Bend tube assembly toinsurer proper positioning

C

C

Torque to 250 in. lbs.

Torque to 200 in. lbs.

A A

Torque to 100 in. lbs.

32

33

26

30Ref.

2

12

6

13

22

23

16

15

14

20

27

1

28

11

6608068065660786607794414560801056020106622093585680796808168089925506808368080680876602868074

HIGH PRESSURE PLATE ASSEMBLY#68090

Item

123456789

101112131415161718

Control Descr. Qty.

111112114411112111

Scr. Adj.CartridgeGuide BallSprg. Hi-FlowBallB-U WasherO'RingRelief Vlv.S.H.C.S.Gasket Wshr.Ck. ValveSpringBallS.H.C.S.Gasket Wshr.Pilot Spl.Brg. w/SealH.P. Plate

660379090666042660396604066043660466605166049

PISTON BLOCK ASSEMBLY#66231

Item

12345789

10

Control Descr. Qty.

121111111

Block PistonBallSpringWasher/CopperScrew SpringBall Retain.Intake-SeatSprg PistonPiston

Item

123

680479394968053

LOW PRESSURE PLATE ASSEMBLY#68192

Control Descr. Qty.

151

Low Pres. PlatePipe PlugBushing

1418

1095431

28

1312

11

Figure 5B

6

17

7

6

16

1 2 3 4 5

9

10

7

8Figure 5C

2

Figure 5D

1

3

.157

12

CYLINDER ASSEMBLY#88053

83 5 4 2

7 1 10 9

Tighten Screws to80 Ft. Lbs. Torque.

.18 Ref.

7Dia. Ref.

Figure 6

6

23.42 Ref.

2-Ports (In Line) Relief Valve Port16Ref.

8805288050880545602251*5608251*93750*85371*56012079*8779385855

Item

12345678910

Control Descr. Qty.

1111111114

Cyl. Bdy. WeldPiston RodHead GlandO'RingB-U RingRod SealPiston SealRod WiperSteel PlateScrew

* Items are included in the Packing Kit#54381.

13

CONTROL VALVE ASSEMBLY#88473

184626831093598939506832488076880788635388079

Item

123456789

Control Description

Control ValveManifold (Barksdale Val.)S.H.C. Screw 3/8 - 16 x 2 Lg.Pipe Plug - Flush TypeGasket1/4 x 1 1/2 Hex Nipple1/4 Female Pipe Swivel Adpt.3/8 x 2 Hex Nipple3/8 Female Pipe Swivel Adpt.

Qty.

114211111

3

1

2

4

5

8

9

7

6

1/4 - 18 NPTFGage Port(Retract)

Torque to 300 In.Lbs.

1/4 - 18 NPTFGage Port(Extend)

Figure 7

14

"A" "A"

A

21

201918

22

View "A-A"

17

16

15

7

14

13

12

11

1

23

4

6

5

10

9

8

5

VALVE#18462

ITEM

12345678910111213141516171819202122

DESCRIPTION

Rotor AssemblyO'RingSubplate-Valve.O'RingThrust WasherThrust BearingO'RingUpper Valve Blk.Detent & Stop Plt.Driv-Lok PinO'RingBack-up WasherShear SealSpring WasherDetent SpringBall .250 Dia.Washer-HandleFlat GripHandleAcorn Nut 1/2-20Soc. Hd. CapscrewO'Ring

QTY.

1411211111333311111121

INTERCHANGEABLE WITH #85764

Figure 7A

15

CONTROL #

6816056020112681805602225680266815556020126803568024938045602011658826818168028680259254968032681576803368034987385602008

HANDLE SUPPORT ASSEMBLY#85464

8546085494854958549685497

Item

12345

Control Description

SupportPinNutSpringRetaining Nut

Qty.

11111

Figure 8

1

5

4

2

3

16

PARTS LIST - AIR MOTOR#85501

Figure 30

4

5

7

20

6

17

16

12

18

9

11

82

10 10

3

19

13

14

1

15

Item

123456789

1011121314151617181920

60280826028083602808460280856028086*6028087*6028088*6028053*6028089*6028090*60280916028092*60280936028094*60280966028097602809860280546028055*60281076028099

Control Description

BodyEnd Plate, DriveEnd PlateRotor AssemblyVaneVane SpringPush PinBearing, Drive EndShaft SealBody Spacer GasketEnd Cap, Drive EndO'RingEnd Cap, DeadEnd Cap GasketMuffler AssemblyFeltScreenDrive KeyBearing, Dead EndDowel PinRepair Kit, Motor

Qty.

11114421121111112114

*Items Included in Repair Kit #6028099

17

FILTER - LUBRICATOR ASSEMBLY#18233

Air Pressure Inlet

Bracket#86454

Lubricator#86242 To Motor Inlet Port

1/2" Union - #86245

Figure 10

1/2" Steel Pipe Nipple#88063

Air Fliter#86241

1/2" Steel Pipe Nipple#87320

1/2" Steel Pipe Nipple#88063

Coupling#88065

Elbow#86243

Oil DropRegulator

Fill Plug

Nipple#88063

Elbow#86244

Nipple#87316

Elbow#88064

18

100 TONPOW'R-RISER

44" MINIMUM

POW'R-RISER SUB-ASSEMBLY44 INCH MINIMUM

ITEM

123456789101112131415161718192021222324252627282930313233343536373839404142

QTY.

111121321211111112222146222421

16611112111

CONTROL #

8820285464854658545185457877748615585468840278547088057879730188060880688547386353181071810993950560244195306854759359485855938668547793930939439378268000

8820486006939445502486225181178485388066880598805818970

DESCRIPTION

Cylinder AssemblySupport AssemblyHandle AssemblyHousing Reservoir (Machined)Handle (MachinedºRing1/4"-20 x 1/2 Set ScrewShaftRelief Valve (10,000 lbs.)16 x 4 Semi-Pneu. Tire & Wheel5" Lg. NippleOver Center Valve1/4" x 17" Hose Assembly/Spg.3/8" x 19" Hose Assembly/Spg.3/8" x 1/4" Pipe Nipple3/8" x 2" Lg. Pipe Nipple3/8" x 90 Elbow3/8" x 90 Street Elbow1/4" Socket Pipe Plug7-1/2" x 7" x 1/4" O-Ring3/8" x 2" Lg. Roll Pin1/2" x 2.5" Lg. Roll Pin3/8"-16 x 1" Lg. Soc. Hd. Cap Screw5/8"-11 x 1-1/2" Lg. Ft. Hd. Hex Cap3/4"-10 Hex. Slotted Nut1-1/8"-12 Hex. Jam Nut3/4" Plate Washer3/8" Lock Washer1/8" x 1-1/4" Cotter PinBreather Vent & Filter

Base7/16"-14 x 1-1/2" Lg. Hex. Hd. Screw7/16" WasherSafety Valve Enclosure Kit3/8" Threaded Eye Bolt3/8" Swivel FittingCaution DecalSpacer (1/4 Thick)1/4" x 90 Elbow1/4" x 3-1/2" Lg. Nipple1/4" x 90 St. Elbow

USE FIG. 11

19

POW'R-RISER SUB-ASSEMBLY44 INCH MINIMUM

USE FIG. 11

43

7 6

21

20

5

4

11

17

1

14

12

20

24 32

33 34 16 18

37 40

19 41

42

13

10

18

3

22

2

36 23 28

28Torque to .150 In. lbs.

1.25

43.17

41

40DRAW

NOTE: For part numbers no shown in Fig. 11-12 (44" Min.), referto standard Pow'r-Riser Fig. 1-5D and 7-10.

20

CYLINDER ASSEMBLY 44 INCH MINIMUM#88202

8 3 5

4 6

2 7

1 10 9

.18 REF

41.87 REF.

Tighten Screwsto 80 Ft. lbs.Torque.

7DIA. REF.

NOTE: Items with * are included in the packing kit #54381 Figure 12

8820188050880545602251*5608251*93750*85371*56012079*8820385855

Item

123456789

10

Control Descr. Qty.

1111111114

Cyl. Bdy. WeldPiston RodHead GlandO'RingB-U RingRod SealPiston SealRod WiperSteel PlateScrew

Relief Valve Port2-Ports (In Line) 16REF.

21

MAINTENANCE INSTRUCTIONS

A. OIL

1. The "full level" of the reservoir is approximately 5 gallons. Fill within 2" from the topof reservoir as needed. Check regularly.

2. The use of Simplex oil is highly recommended. Simplex oil contains a completeadditive package including anti-wear, oxidation inhibitors and anti-foam additives.NOTE: USING OIL WITH IMPROPER VISCOSITY WILL DAMAGE PUMPCOMPONENTS.Inspect the oil once a week:

Visual -- look for water or solid contaminants. Compare color to new oil."Milky" oil must be changed.

Touch -- compare used oil to new oil for grittiness by rubbing between yourfingers. Gritty oil must be changed.

Normally change the hydraulic oil after every 50 hours of operation or every 90 days,whichever occurs first.

3. Water in the reservoir can deteriorate oil and damage pump components. Onesource of water contamination is from the condensation of ambient air in the reservoir. To minimize this condition, keep the jack fully retracted and the reservoir fullwhen not in use.Water can be drained from jacks that have sat idle for 8 hours, as water accumul-ates in the bottom of the reservoir. Tilt the jack back and when the drain plug (#19,fig. 4) is at its lowest point, open and drain off the water.The amount of water that gets in the reservoir will vary, and under most conditions,draining may not be necessary provided the oil is changed regularly. However, ifyou suspect that water has entered the reservoir from any manner (rain, washings,etc.) or if the jacks are subject to significant changes in temperature where conden-sation will occur inside the reservoir, drain the water as needed, or better yet,change the oil completely.

B. PUMP ASSEMBLY (Note: For pump removal details, see page)

1. Clean Oil Filter Screen Periodically.

a. Loosen and remove reservoir plate bolts and retract tube assembly (#10, fig. 3).Lift pump unit off the reservoir being careful not to damage the gasket.

b. Unscrew screen from bottom of pump unit and clean with nonflammable solvent.c. Blow dry and reassemble.

22

MAINTENANCE INSTRUCTIONS (CON'T)

B. PUMP ASSEMBLY (Con't)

2. Flushing the Pump. If you suspect your pump has been contaminated or discoversludge or other deposits on internal components, you should thoroughly flush thepump.

a. Remove the old oil from the reservoir, then thoroughly clean the reservoir andrefill with a clean, 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. 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 frompump assembly). Refill the reservoir with Simplex #9 hydraulic oil andreassemble the pump to the reservoir assembly.

C. AIR MOTOR AND FILTER LUBRICATOR

The air motor is a precision built rotary type motor. The top clearance (between rotorand bore) is .0015". The total end clearance (between the sides of the rotor and theend plates) is .002". The vanes take up their own wear and will last 5,000-12,000hours, depending upon speed, method of oiling, operating pressure, and precautionstaken in maintaining the motor. The type of shaft seal used does not lend itself to oper-ating pressures above 100 PSI (6.89 Bar-Metric). Allowing excess moisture or foreignparticles from the air line to enter the motor will nullify the guarantee.

Install a moisture trap and filter in the air line ahead of motor, for efficiency of output andcontrol of speed, use air lines of not less than 3/4 inch pipe size. When coupling orconnecting the motor to a driven member, avoid any end or side thrust on the outputshaft and especially DO NOT HAMMER ON SHAFT.

The starting torque is less than the running torque and could vary depending on theposition at which the vanes stop in relation to the air intake port. The speed and torquecan be regulated by using a pressure regulator or a simple shut-off valve. Lubrication isnecessary for the shaft seals, and rust prevention. It can be accomplished by the instal-lation of an automatic air line oiler set to feed 1-3 drops per minute. Use Simplex#18243 anti-freeze oil. Excessive moisture in the air line can cause rust formation in themotor and might also cause ice to form in the muffler due to expansion of air throughthe motor.

If the motor is sluggish or inefficient, try flushing with solvent in well ventilated area.Disconnect the air line and muffler and add several teaspoons full of solvent. Rotate theshaft by hand in both directions for a few minutes, again connect the air line and applypressure slowly until there is no trace of solvent in exhaust air. (Keep face away fromexhaust air). Check the muffler felts for grease, dirt, etc. If dirty, wash them in solvent.Replace the felts and connect the muffler. Relubricate the motor with a squirt of oil inthe chamber. If the vanes need replacing, or foreign particles are present in motorchamber, an experienced mechanic may remove the end plate opposite the drive shaftend.

DANGER TO PREVENT EXPLOSIVE HAZARD, DO NOT PUMP COMBUSTIBLELIQUIDS OR VAPORS THROUGH THESE UNITS.

23

MAINTENANCE INSTRUCTIONS

PARTS ARE DESIGNATED WITHIN PARENTHESES BY FIGURE NO. & ITEM NO.,i.e., (4-17) indicates (Figure 4 - item 17)

D. DISASSEMBLY DETAILS (Refer to Figures as noted)

Pump Removal (Note: Make sure that pressure is released before working on this jack.To assure that pressure is released, shift the directional control valve (3-9) through allthree positions a few times with the air disconnected. Failure to release pressure mayresult in injury.

a. Drain reservoir by removing plug, #93950 (4-19).b. Disconnect tube assembly, #88067 (3-10).c. Remove (14) mtg. screws, #93582 (3-13).d. Lift the left side of pump mtg. assembly, disconnect hose assemblies #85471 (4-13)

and #85472 (4-14), from the bottom of pump mounting assembly.e. Carefully remove pump mtg. assembly.

Cylinder Piston Removal (Seal Replacement) (Refer to Figures 3 & 6)

a. Remove load cap, #18333 (3-10).b. Raise the piston almost all the way up.c. Remove head gland nut, #88054 (6-3). Take piston rod, #88050 (6-2) out from the

cylinder.

Cylinder Body Removal (Refer to Figures 4 & 6)

a. Follow pump removal steps (a-e) above.b. Remove hoses, #85471 (4-13) and #85472 (4-14).c. Remove overcenter valve assembly (Fig. 4, View A-A)d. Remove pipe nipple, #86353 (4-16) along with elbow #18109 (4-18)e. Remove pipe nipple, #85473 (4-15) and relief valve, #84027 (4-9)f. Remove (6) aluminum base mtg. screws, #86006 (4-33) and (30) washers #86007

(4-34).g. Take off nylon washer, #85853 (4-31); remove (6) mtg. screws, #85855 (4-24).h. Remove ring, #87774 (4-6).i. Remove steel plate mtg. screws, #85855 (6-10).j. Pull off reservoir, #85541 (4-34), from cylinder.k. Remove gland nut, #88050 (6-3).l. Take out piston rod, #88054 (6-2).m. Replace seals as required.n. Reassemble in reverse order. (See following notes.)

Care must be taken to reassemble (39) washer #86077 (4-34) in the same pattern asshown in Figure 4.

24

TROUBLESHOOTING

If the procedures listed below do not remedy the problem--the pump willrequire service and should be taken to an authorized Simplex servicecenter for repair.

Problem Cause -- Solution

Sporadic Cylinder Action

Noisy Operation

Pump Oil is Overheating

Pump runs by will not pump oil, or pistonrod moves by will not lift load.

Piston extends by will not retract.

1. Air in the hydraulic system. Cycle the jackseveral times under no load.

2. Check reservoir oil level.

1. Air in system. (Same as Above)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 withSimplex #9.

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

3. Oil level is low. Fill reservoir to normallevel.

4. See #1 of page 3.

1. Pump is not primed. Run pump a fewminutes, tipping jack back and forth.

2. Check internal relief valve.3. Flush filter screen.4. Defective control valve. (Troubleshoot

separately or replace valve).5. Replace o-ring (6 & 7, Fig. 5B)6. Damaged o-rings. Take to nearest

Simplex service center for repair.

1. Pump not developing enough pressure.(2,500 PSI required for retraction)a. Check for internal pressure leaks.b. Adjust internal relief. (#8, Fig. 5B)c. Replace o-rings. (#6 & 7, Fig. 5B)

2. Defective O.C. Valve (#12, Fig. 4)Replace.

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