simplex hydraulic pump manual free sample

••• 2 •••G5 Torque PumpIMPORTANT - READ CAREFULLYThis manual contains important information for the correct installation, operation and maintenance of thisequipment. All persons involved in the installation, operation and maintenance of this equipment must bethoroughly familiar with the contents of this manual. To safeguard against the possibility of personal injury orproperty damage, follow the recommendations and instructions of this manual. Keep this manual for reference.WARRANTY STATEMENTSIMPLEX products are warranted to be free of defects in materials and workmanship under normal use foras long as the original purchaser owns them, subject to the guidelines and limitations listed. This warranty doesnot cover: normal wear & tear, cosmetic items, abuse, overloading, alterations, improper fluid, or use in amanner for which they are not intended. If the customer believes a product is defective, the product must bedelivered, or shipped freight prepaid, to the nearest SIMPLEX Authorized Service Center for evaluation andrepair.1.0 RECEIVING INSTRUCTIONSImportant! Make sure to inspect all of the components for shipping damage. If damage is found, notify carrier atonce. Shipping damage will not be covered by warranty. The carrier is responsible for all loss associated withshipping damage.

2.0 SAFETY••• 3 •••Make sure to read the instructions, warnings and precautions carefully. Follow any recommended safety precautionsto avoid personal injury or damage to the unit. Simplex cannot be responsible for any damage or injury from unsafeuse, lack of maintenance or incorrect operation. In the event any questions or concerns arise, contact SIMPLEX or alocal Distributor for clarification.The pump’s maximum working pressure is 10,000 PSI (700kg/cm 2 ). Makesure that all hydraulic equipment such as tools, hoses, etc. used with thispump are rated at 10,000 PSI (700kg/cm 2 ) operating pressure.If you have never been trained on high-pressure hydraulic safety, consultyour 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 orpersonal 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 damageto, 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/cm 2 ). Do not connect a tool to a pump with ahigher 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 inthe system. Install pressure gauges in the system to monitor operating pressure. It is your window to what ishappening in the system.CAUTION: Avoid damaging hydraulic hose. Avoid sharp bends and kinks when routing hydraulic hoses. Using abent or kinked hose will cause severe back-pressure. Sharp bends and kinks will internally damage the hose, leadingto premature hose failure.Do not drop heavy objects on hose. A sharp impact may cause internal damage to hose wire strands. Applyingpressure 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 meansof safe transport.CAUTION: Keep hydraulic equipment away from flames and heat. Excessive heat will soften seals, resulting in fluidleaks. Heat also weakens hose materials. For optimum performance do not expose equipment to temperatures of65° 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 seriousinjury. 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 becomesseverely overloaded, components can fail catastrophically causing severe personal injury or death.www.tksimplex.com

3.0 TECHNICAL SPECIFICATIONS••• 4 •••G5 Electric Torque WrenchVoltage 115V 230VOperating Pressure 10,000 PSI (700kg/cm 2 )Electrical Power Source 20 Amps 115V Grounded 50/60 Hz 10 Amps 230V Grounded 50/60 HzMotor RatingFlow RateMaximum OperatingTemperature4.0 WORKING PRESSURE1.125 Hp Single Phase18 Amps @ 10,000 psi (700kg/cm 2 )1.125 Hp Single Phase10 Amps @ 10,000 psi (700kg/cm 2 )575 cu. in./ min. @ 1,100 psi, 55 cu. in / min. @ 10,000 psi170̊F - (65̊C)The pump’s maximum working pressure is 10,000 PSI (700kg/cm 2 ). Make sure that all hydraulic equipment such asrams, hoses, etc. used with this pump are rated at 10,000 PSI (700kg/cm 2 ) operating pressure.4.1 INSTALL VENT PLUGRemove SHIPPING PLUG (A) and install VENT PLUG (B) into fill plug.4.2 ADDING OILRemove OIL FILLER CAP (C) and add SIMPLEX Hydraulic Oil into reservoir.Oil level should not exceed 1” from the reservoir cover.BAC*As a “rule of thumb” oil should be visual in site window when the unit ispowered down and all connected tools are retracted.4.4 ELECTRICALCheck for proper electrical supply before connecting. Be sure the electrical connection is grounded. Check that yourpower 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 OFCONDUCTIVE 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 fit the proper groundedtype electrical outlet. Do not use a two prong ungrounded extension cord as the pump’s motor must begrounded.4.5 CONNECTING HYDRAULIC TOOLSUse only tools, hoses and accessories rated at 10,000 PSI (700kg/cm 2 ). When making connections with quickdisconnect couplings, make sure the couplings are fully engaged. Threaded connections such as fittings, gauges,etc. must be securely tightened and leak free. Use 1.5 wraps of Teflon tape (or suitable thread sealant) on all threads,leaving the first complete thread free of tape to ensure no foreign matter enters the hydraulic circuit.4.6 STARTING THE PUMP FOR THE FIRST TIME1. 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 •••CAUTION: Never operate the pump without tool movement for more than 1 minute. Leaving the valve in the advanceor retract position without the tool’s piston rod moving will overheat the oil.CAUTION: Never disconnect or connect any hydraulic hoses or fittings without first unloading the tool, then unplugthe electrical cord of the pump. Open manual relief valve to assure that the system has been depressurized. Viewthe gauge reading and double check the gauge to assure pressure has been released.4.7 PUMP MOUNTINGRefer to the chart for mounting dimensions to secure the pump to a fixed surface.1.5 gal.(6L) 2.5 gal.(10L) 5 gal. (20L)A 15.13 17 19.6B 1.68 2.75 4.69DBACC 3.57 4.37 5.03FD 1.43 1.93 2.93EE 8.75 9.75 11.75F1/4-20unc(4 places)1/4-20unc(4 places)1/4-20unc(4 places)5.0 CONTROL VALVES2 Position - 4 Way Solenoid2-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 SWITCHESRemote pendant.Configured 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.Motor/Valve Control PendantNOTE: 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 themotor “ON” to continue, or unplug / re-plug the unit into power supply, thendepress the motor “ON” to continue.www.tksimplex.com

5.2 PRESSURE TORQUE SETTING••• 6 •••WARNING: Make these adjustments BEFORE putting torque wrench on nut or bolt head. The pump pressuresetting may be above the pressure needed to provide the required torque for your application. Exceeding requiredtorque will cause equipment damage and may lead to serious personal injury.Adjusting Knob1. See torque wrench instructions for amount of pressure requiredto produce desired torque.2. Loosen lock nut and back out relief valve to prevent unintendedpressure build up.3. Turn pump on. Press and hold the “ADVANCE” button, and readpressure on the digital display on the pendant. (Manual Mode)4. While holding the button, turn relief valve in (clockwise)to increase pressure or out (counter-clockwise) to decrease maximumpressure.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 before setting tool on the nut.DIAGNOSTIC MODELock NutValve Assembly• Highlight & Press “enter” to select DIAGNOSTIC MODE. ❶• DISPLAY TEST - Highlight & press “enter” to select DISPLAY TEST. Press“enter” again to end the test. ❷Press “left” arrow button to return to MAIN MENU.• KEYPAD TEST - Highlight & press “enter” to select KEYPAD TEST. Pressany button to test. Press “menu” to exit. ❸• CIRCUITRY TEST - Highlight & press “enter” to select CIRCUITRY TEST. Ifcircuit diagnostic is OK, press any key to exit. ➍Press “left” arrow key to return to MAIN MENU.5.3 AFTER COMPLETING THE JOB❷☞❸☞➍☞DIAGNOSTIC MODEDISPLAY TESTKEYPAD TESTCIRCUITRY TESTPower Control CenterADVANCEONBefore disconnecting hoses, fittings, etc., first be sure the tool is unloaded andretracted, then unplug the power cord. The pump is designed to cycle valveupon power down “off.”6.0 PERIODIC MAINTENANCECompletely change the hydraulic oil and clean the intake screen and magnet(located in the reservoir) twice a year. If equipped, change the external oil filtertwice a year (Use Simplex oil only, Model # AO1, 1 gallon). Change the oilmore frequently when used in extremely dusty areas or when the oil has beenoverheated. Using oil other than Simplex Brand may void the pump’s warranty.❶☞OFFMENUENTERThe 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 thereservoir.• 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 maintenanceor repair procedures.

6.1 MAINTAIN OIL LEVEL••• 7 •••Check hydraulic oil level every 30 hours of operation (sight gauge should be completely covered in oil when all toolsare retracted. Add Simplex oil (Model # AO1 – 1 gallon) when necessary. Oil level should be no more than 1” from topof reservoir plate – with tools retracted and motor off.6.2 CLEAN OIL INTAKE SCREEN ONCE A YEARLoosen 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 first stage gear pump. Care should be takennot to remove the center plate and gears. Remove and clean with non-flamable solvent and blow dry clean. Reinstallin reverse order and torque bolts to 75 inch pounds. Keep the motor and pump as clean as possible.6.3 FLUSH THE PUMPIf you suspect your pump has been contaminated or discoversludge or other deposits on internal components, you shouldthoroughly flush the pump. Remove the old oil from the reservoir,then thoroughly clean the reservoir and refill with a clean,nonflammable flushing oil. Reassemble the pump and motor tothe reservoir.Run the pump in no load condition for 1 or 2 minutes maximum.Unplug the pump and remove the motor and pump assemblyagain. Now drain the flushing oil and re-clean the inside of thereservoir. (Make sure flushing fluid is also drained from pumpassembly). Refill the reservoir with Simplex hydraulic oil andreassemble the pump.Oil Fill (1.5 - 2.5 Gal. Models)Sight GaugeDrain Plug (1.5 - 10 Gal.)www.tksimplex.com

PENDANT OVERVIEW••• 8 •••LCD DISPLAYPower Control Center“ADVANCE” BUTTON”DEPRESSING BUTTON ACTIVATESMOTOR “ON” AND ADVANCES TOOL.ADVANCE“ON” BUTTON”DEPRESSING BUTTON ACTIVATESMOTOR “ON”ON“OFF” BUTTON”DEPRESSING BUTTON TURNSMOTOR “OFF” AND CYCLES VALVE TORELIEVE PRESSURE TRAP.OFFMENU / ENTER / ARROW BUTTONSEXECUTES A COMMANDMENUENTER• UP BUTTON MOVES CURSOR UPWARDCHANGES VALUE• DOWN BUTTON MOVES BUTTON DOWNWARDCHANGES VALUE• LEFT BUTTON MOVES CURSORLEFT OR RETURNS BACK• RIGHT BUTTON MOVES CURSORRIGHT OR CHANGES VALUENOTE: WHEN IN MANUAL MODE -PRESSING THE “UP” ARROW DARKENS CONTRASTPRESSING THE “DOWN” ARROW LIGHTENS CONTRAST

PENDANT - START UP••• 9 •••Upon “Power Up”, unit will perform system check. If critical fault(s) are detected, unit will not start and fault(s) will bedisplayed 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.PERFORMING SYSTEMCHECKOKSOFTWARE VER. X.XTORQUE WRENCHPower Control CenterPower Control CenterADVANCEFIG. 1 FIG. 2ADVANCEONONOFFOFFMENUENTERMENUENTERwww.tksimplex.com

MAIN MENU - FIG. 3••• 10 •••FIG. 3To 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 highlighted,press the “MENU/ENTER” button to go into that sub-menu mode. ❶To return to the “main menu” press the “left arrow button”.Power Control CenterUNIT SETTINGS - FIG. 4ADVANCE• Highlight & press “enter” to select UNIT SETTINGS. ❶ON• MODE - PRESSURE or TORQUE is chosen by highlighting & pressing “enter” button. ❶To return to the “main menu” press the “left arrow button”.• UNITS - In PRESSURE mode, units (kg/cm 2 , PSI, Bar and KPA) are displayed byhighlighting & pressing the “enter” button until desired form of measurement is displayed. ❸To 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”. ➎To return to the “main menu” press the “left arrow button”.❶☞OFFMENUENTER• UNITS - In TORQUE mode, “units” (lb-ft, NM, KPM,) are displayed by highlighting &pressing the “enter” button until desired form of measurement is displayed. ❸To 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”. ➎To return to the “main menu” press the “left arrow button”.❷☞❸☞➍☞➎☞FIG. 4• TOOL - Highlight & press “enter” and use the “arrow” buttons until the desired TOOL isselected. If the TOOL being used is not a SIMPLEX TOOL, select “other”. If no TOOL is beingused, select “none”. ➍To 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”. ➎To return to the “main menu” press the “left arrow button”.MANUAL MODE - FIG. 5❶☞Power Control CenterADVANCEONOFFMENUENTER• Highlight & press “enter” to select MANUAL MODE. ❶• To operate pump, press the “ADVANCE” button to turn pump motor on andadvance the tool. ❷To return to the “main menu” press the “menu/enter button”. FIG. 5❷☞Power Control CenterADVANCEONOFF❶☞MENUENTER

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 isbeing used, select “none”. ❷To return to the “main menu” press the “left arrow button”.❷☞❸☞➍☞AUTO CYCLE MODETOOLMODETARGET• 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. ❸To return to the “main menu” press the “left arrow button”.Power Control CenterADVANCE• 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” arrowkeys to select the desired digit column. ➍To return to the “main menu” press the “left arrow button”.• RUN - Highlight & press arrow key “down” and press “select” to run theAUTO-CYCLE mode. Unit will AUTO-CYCLE until the target goal is achieved. Tointerrupt during a cycle, depress any button.To return to the “main menu” press the “left arrow button”.❶☞ONOFFMENUENTERHISTORY MENU• Highlight & press “enter” to select HISTORY MENU. ❶• MOTOR RUN TIME - Highlight & press “enter” to view the total number of HOURSand CYCLES for the desired selection. ❷To return to the “main menu” press the “left arrow button”.• WARNING HOURS - Highlight & press “enter” to view the WARNING TIMEtotal. ❸To 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”. ➍❷☞❸☞➍☞HISTORY MENUMOTOR RUN TIMEWARNING HOURSFAULT TIMESPower Control CenterADVANCEONOFF❶☞MENUENTERwww.tksimplex.com

7.0 TROUBLESHOOTING••• 12 •••PROBLEMCAUSE-SOLUTIONSporadic 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 adequatesize.• Have motor checked for proper operation.• Have qualified 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 filled 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 orrelief valve).• Oil level is low. Fill reservoir to normal level, or retrofit the pump withlarger reservoir or heat exchanger.Pump Runs But Will Not Pump Oil: • Pump is not primed. Run pump a few minutes tipping from side toside.• Inspect to make sure that external adjustable relief valve is setproperly.• Defective control valve, take to nearest Simplex Authorized ServiceCenter for repair.• Incorrect motor rotation, take to nearest Simplex Authorized ServiceCenter for repair.• Check to make sure the intake screen is not clogged. Clean ifneeded.• 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 THEORIGINAL PURCHASER OWNS THEM, SUBJECT TO THE GUIDELINES AND LIMITATIONS LISTED. THIS WARRANTY DOES NOT COVER : NORMAL WEARAND 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 SIM-PLEX AUTHORIZED SERVICE CENTER FOR EVALUATION AND REPAIR.2525 GARDNER ROAD, BROADVIEW, IL 601551.800.323.9114 • Outside U.S. 1.708.865.1500www.tksimplex.com

46236Power Control Centerdepressed for 5 seconds, thepower pump will shutdown.TO RESTART PUMPPress the On button to restart.If problem persists, unplugthe line cord fromoutlet to reset.46353R777 OAKMONT LANE, SUITE 800 WESTMONT, IL 605591.800.323.9114 • Outside U.S. 1.708.865.1500www.tksimplex.comG4 SERIESELECTRIC POWER PUMPPARTS IDENTIFICATION MANUALReference # TD060Rev. - BDate - 1/12This illustration is for reference purposes only. Theappearance of your unit may differ from the unit shown.Pendants - pg. 3-4ADVANCERETRACTIION/OFFPENDANT FUNCTIONIn event multiple buttons areElectrical Brackets WiringDiagrams - pg. 17-18Valve Sub-Assemblies- pg.10-12Manifold Sub-Assemblies- pg. 13-14Pump Sub-Assembliesand Sub-Components- pg. 5-9SeriesG1.5 hp41,1 Kw46635Common Componentsused in allG4 Series pumps - pg. 3-4Reservoirs - pg. 19

46236Power Control CenterIPENDANT FUNCTIONIn event multiple buttons aredepressed for 5 seconds, thepower pump will shutdown.TO RESTART PUMPPress the On button to restart.If problem persists, unplugthe line cord fromoutlet to reset.46353IRG4 Series ElectricPower PumpHow to Identify Partsfor Your Model.MODEL MATRIXUnderstanding our model number configurations:PUMPCLASSSample Model #: G 4 1 4 3 L M RModel Performance Series Power Consumption Valve Function Reservoir SizeDescription: 0 = Dump 2 = 1.5 GalG = Gen II Pump1 = 115 VAC4 = 1.5 HP1 = Dump 2 Way 3 = 2.5 Gal2 = 2 Way Manual 5 = 5 Gal2 = 230 VAC3 = 3 Way Manual 6 = 10 Gal4 = 4 Way Manual 7 = 20 Gal5 = 2 Way Solenoid6 = 3 Way Solenoid7 = 4 Way Solenoid8 = Port BlockPUMP TYPEOPTION 1OptionsOPTION 2OPTION 3C = Caster Wheel KitD = Dig. Pressure GaugeF = Foot Switch (motor)G = Gauge (intergrated)H = Heat ExchangerL = Locking Style ManifoldM = Motor PendantO = Oil FilterP = Pressure SwitchR = Roll CageS = Foot Switch (valve)MODEL NUMBER & DATE CODE LOCATIONADVANCERETRACTON/OFFDATE CODE COVER PLATESTAMPING LOCATIONMODEL DECALPLACEMENTSeriesG1.5 hp1,1 Kw4663542

SKIN PUNCTURE/HYDRAULIC LINEBEFORE OPERATING PUMP:1. Be sure the electrical connection is grounded.REVIEW ALL OPERATINGINSTRUCTIONS2. Check that your power supply agrees with the motor nameplate.3. Use only equipment rated for 10,000 PSI / 700 BAR.4. Make sure all connections are tight, secure and kink-free.5. Check the reservoir oil level. Fill to one inch of the top, if necessary.P/N 4511810,000 PSI/700 BAR6. Never operate the pump without tool movement for more than 1 minute without shifting the controlvalve to neutral. Leaving the tool in the advance or retract position without tool movement mayoverheat the oil. Do not exceed oil operating temperatures of 140° F or 60° C.AFTER COMPLETING THE JOB:1. Before disconnecting your equipment, first be sure the tool is unloaded, then unplug the power cordand shift the hydraulic controls several times to release system pressure.2. Store the pump in a clean, dry place.PERIODIC MAINTENANCE:1. Change the hydraulic oil and clean the oil screen, breather and magnet (located in the reservoir) twice ayear. Refer to the operating instructions for details. When used in extremely dusty areas or oil has beenoverheated, change the oil more frequently.68068R46355RG4 Series ElectricPower PumpCommon componentsused in pumpsNOTE: This illustration is for referenceonly. The appearance of your unitmay differ from the unit shown.TORQUE TO250 IN*LBSTORQUE TO75 IN*LBS32 335177157825765355TORQUE TO250 IN*LBS20 218TORQUE TO50 IN*LBS966TORQUE TO150 IN*LBS67PENDANT FUNCTIONIn event multiple buttons aredepressed for 5 seconds, thepower pump will shutdown.TO RESTART PUMPPress the On button to restart.If problem persists, unplugthe line cord fromoutlet to reset.46353ON/OFFI IRETRACTADVANCE46236Power Control Center19544146ADVRET23221713RETRACT HOLD ADVANCE28793ELECTRIC PUMP INSTRUCTIONS FOR SAFE OPERATION5273TORQUE TO 20IN*LBSTORQUE TO 250 IN*LBSUSE REMOVABLETHREAD LOCK477535RETRACTCORDPOWERCORD26 39 ADVANCECORD11MOTORCORD6TORQUE TO250 IN*LBS4147016171SeriesG1.5 hp1,1 Kw46635475 21 TORQUE TO 250 IN*LBSUSE REMOVABLETHREAD LOCK7412 272639242103

G4 Series ElectricPower PumpCommon componentsused in pumpsITEM # DESCRIPTION 115 V. 230 V. QTY.002 PUMP ASM. G4&G6 2 STAGE SEE PAGE 5-7 1.00003 RESERVOIR SEE PAGE 16 1.00004 RESERVOIR GASKET 85469 85469 1.00005 BREATHER VENT 3/8" NPT 46348 46348 1.00006 PIPE PLUG 1/2" FLUSH W/ COATING 46697 46697 1.00007 SAE #12 HEX PLUG WITH PORT 46118 46118 1.00008 HHCS 1/4-20 X .75 PLT 65891 65891 14.00009 SEALING WASHER 65892 65892 14.00010 RESERVOIR DECAL G4 46635 46635 2.00011 LABEL SAFE USE ELEC 68068 68068 1.00012 BLANK DECAL 3 X 4 87305 87305 1.00013 MANIFOLD ASM SEE PAGE 10-11 1.00014 VALVE GASKET 69242 69242 1.00014 VALVE GASKET (4WAY LOCK) 68581 68581 1.00015 SHCS 3/8-16 X 2 1/4 (2WAY, 3WAY & 4WAY) 93598 3.00015 SHCS 3/8-16 X 2 3/4 (LOCK 3WAY/4WAY) 99921 99921 3.00015 SHCS 3/8-16 X 1 1/4 (DUM P VALVE) 93596 93596 2.00016 VAL ADP W/ CHECK ASM 69378 69378 1.00016 VAL ADP (DUMP) 68963 68963 1.00017 HEX PIPE PLG 3/8" (DUM P, 2WAY & 3WAY) 46513 1.00017 HEX PIPE PLG 3/8" W/ COAT (4 WAY) 46513 46513 2.00018 SHCS 3/8-16 X 1.75 (DUM P VALVE) 84692 84692 1.00019 VALVE ASM. SEE PAGE 8-9 1.00020 SHCS 3/8-16 X 3 1/2 (SOLENOID ONLY) 88363 88363 4.00021 LOCKWASHER 3/8 PLATED 93943 93943 2.00021 LOCKWASHER 3/8 PLATED (SOLENOID ONLY) 93943 93943 4.00022 ROLL PIN 1/8 X 3/8 LG (SOLENOID ONLY) 561604 561604 1.00023 RET VLV DECAL (3 WAY M ANUAL) 68199 68199 1.00023 RET VLV DECAL (4 WAY M ANUAL) 68069 68069 1.00023 RET VLV DECAL (3 WAY SOLENOID) 45120 45120 1.00023 RET VLV DECAL (4 WAY SOLENOID) 45118 45118 1.00024 MAGNET 66021 66021 1.00025 HANDLE 1.5 /2.5 GAL RESERVOIR 46378 46378 1.00026 STRAIN RELIEF 3/8 NPT(SOLENOID ONLY) 46059 46059 3.00027 DECAL OVERLAY 46539 46539 1.00028 CONTROL BOX ASM G4 PUMPS SEE PAGE 12-13 1.00031 MEMBRANE SWITCH (NON PENDANT PUM PS) 46246 46246 1.00032 FITTING,CORD L-TIGHT 68375 68375 1.00033 LOCKNUT 1/2 INCH 85510 85510 1.00035 SIMPLEX DECAL 5.71" x 1.15" (SOL /M OTOR PENDANT) 46355 46355 1.00038 RING TERMINAL 1/4" 69917 69917 1.00039 LOCKNUT 3/8 NPT (SOLENOID ONLY) 46340 46340 3.00041 PENDANT ASSEMBLY (SOLENOID & M OTOR) 46220 46220 1.00043 WIRE NUT TAN 84983 84983 3.00046 COIL WITH DIN CONN (SOLENOID ONLY) 46294 46324 2.00047 MOLD DIN CONN W/ CORD (SOLENOID ONLY) 46327 46327 2.00052 SIGHT GAUGE 46009 46009 1.00053 MEMBRANE SWITCH LABEL * * 1.00054 DECAL PENDANT INSTRUCTION * * 1.00055 SIMPLEX DECAL 1.25" x 0.25" * * 1.00066 HEX NUT 5/16-18 ZINC PLTD Y0001045 Y0001045 4.00067 LOCKWASHER 5/16 93942 93942 4.00070 GASKET-MOTOR 66012 66012 1.00071 PUMP GASKET G5 46032 46032 1.00073 COVER PLATE G5 45905 45905 1.00074 PIN,DOWEL 3/16 1" LONG 69026 69026 1.00075 SHCS 3/8-16 X 3/4 LG 97084 97084 4.00076 MOTOR 1 1/2 HP DS1011259 DS1011259 1.00078 FHCS 1/4-28 x 0.50 LONG 46279 46279 4.00079 MOTOR STANDOFF 46392 46392 1.00* G SERIES PENDANT DECAL KIT 54489 54489 1.004

G4 Series ElectricPower PumpPump Sub Assembly(46632SS) PUMP SUB ASM.A15TORQUE TO350 IN*LBS.34TORQUE TO130 IN*LBS22392423943 4810876SECTION A-ABB7516434382A373635211644452628213538TORQUE TO37 400 IN*LBS.113 12TORQUE TO1125 IN*LBS.2025TORQUE TO130 IN*LBSTORQUE TO90 IN*LBS.14TORQUE TO130 IN*LBS19TORQUE TO400 IN*LBS.SECTION B-B442918442750TORQUE TO175 IN*LBS.50TORQUE TO175 IN*LBS.414949TORQUE TO90 IN*LBS.2550TORQUE TO175 IN*LBS.TORQUE TO90 IN*LBS.2550TORQUE TO175 IN*LBS.47TORQUE TO150 IN*LBS.1246TORQUE TO150 IN*LBS.1225 TORQUE TO90 IN*LBS.TORQUE TO75 IN*LBS.30TORQUE TO130 IN*LBS3132TORQUE TO90 IN*LBS.2532TORQUE TO75 IN*LBS.333132TORQUE TO75 IN*LBS.25TORQUE TO90 IN*LBS.2517TORQUE TO90 IN*LBS.5

G4 Series ElectricPower PumpPump Sub Assembly(46632SS)PUMP SUB ASM.ITEM# DESCRIPTION PART # QTY1 PUMP BODY G5 45750 12 BEARING ROLLER 5/ 68360 13 THRUST BEARING 66033 14 THRUST WASHER 66474 25 ECCENTRIC SHAFT SEE PAGE 9 16 THRUST BEARING 66106 17 THRUST WASHER 66108 28 ECCENTRIC SHAFT 45908 19 O-RING 1 7/8X2" U 56020322 110 RETAINING RING 68978 111 POWR BUD DUMP PLU 43283 112 O-RING 3/16X5/16 5602008 313 BACKUP WASHER 56080087 114 MALE TEE 1/8 PIPE 45426 115 1/4 FLUSH PLUG W/ 46509 116 UNLOADING PISTON SEE PAGE 9 217 MALE ELBOW 1/4 TU 45929 118 BALL 1/8" 90906 419 PISTON BLOCK TUBE 46548 120 OUTLET TUBE PISTO 45815 121 BALL 5/16" 91701 322 UNLOADING SPRING 43671 123 ADJUSTING SCREW G 45903 124 O-RING5/8X3/4 URE 56020162 125 1/16 FLUSH PLUG W 40049 727 PLATE-BOTTOM 68849 128 GEAR SET 3/8" CLY 68855S 129 SHAFT-IDLER 68850 130 SCREEN 68921 131 TUBE-GUIDE .22 68922 232 SHCS 1/4-28 X 1 3 68255 533 PLATE-SCREEN MTG. 68927 134 MALE ELBOW 1/8 PI 69354 135 SPRING 68225 236 ROLL PIN 1/8 X 3/ 97782 137 BALL STOP G5 45904 238 GASKET 29/64 X 5/ 86269 239 SPRING CAP UNLOAD 43673 141 TUBE RETURN 68569 143 BEARING ROLLER 1 66030 144 BEARING ROLLER 1/ 68891 345 RING-RETAINING 68892 146 1/8 FLUSH PLUG W/ 46508 147 CART REL. VAL. AS 66220SS 148 SHAFT SEAL G5 45930 149 PISTON BLOCK ASM SEE PAGE 9 250 SOCKET HEAD CAPSC 69392 86

G4 Series ElectricPower PumpPump Sub Assembly(DS1319900SS) DUMP PUMP SUB ASM.SECTION A-AA15TORQUE TO350 IN*LBS.34TORQUE TO130 IN*LBS22392423943 481081676BB75433837TORQUE TO400 IN*LBS.A3738363521164445422628TORQUE TO90 IN*LBS.212535120TORQUE TO130 IN*LBS14TORQUE TO130 IN*LBS19TORQUE TO400 IN*LBS.SECTION B-B184429184427CC50TORQUE TO175 IN*LBS.50TORQUE TO175 IN*LBS.41494950TORQUE TO175 IN*LBS.TORQUE TO90 IN*LBS.2550TORQUE TO175 IN*LBS.47TORQUE TO90 IN*LBS.25TORQUE TO150 IN*LBS.12SEE DETAIL "D"1225TORQUE TO90 IN*LBS.TORQUE TO130 IN*LBSTORQUE TO75 IN*LBS.31 32TORQUE TO120 IN*LBS.4659 6030TORQUE TO25 IN*LBS.11DETAIL C-C1258TORQUE TO3275 IN*LBS.DETAIL "D"13573361515631 32TORQUE TO75 IN*LBS.5225535455TORQUE TO90 IN*LBS.2517TORQUE TO90 IN*LBS.7

G4 Series ElectricPower PumpPump Sub Assembly(DS1319900SS) DUMP PUMP SUB ASM.ITEM# DESCRIPTION PART # QTY1 PUMP BODY G5 45750 12 BEARING ROLLER 5/8x13/16 68360 13 THRUST BEARING 66033 14 THRUST WASHER 66474 25 ECCENTRIC SHAFT ASSEMBLY SEE PAGE 9 16 THRUST BEARING 66106 17 THRUST WASHER 66108 28 ECCENTRIC SHAFT ADAPTER 45908 19 O-RING 1 7/8X2" URE 56020322 110 RETAINING RING 68978 111 SEAT, INSERT 68482 112 O-RING 3/16X5/16 5602008 313 BACKUP WASHER 56080087 114 MALE TEE 1/8 PIPE TO 1/4 45426 115 1/4 FLUSH PLUG W/SEALANT 46509 116 UNLOADING PISTON ASSEMBL SEE PAGE 9 217 MALE ELBOW 1/4 TUBE 1/4 45929 118 BALL 1/8" 90906 319 PISTON BLOCK TUBE G5 46548 120 OUTLET TUBE PISTON BLOCK 45815 121 BALL 5/16" 91701 322 UNLOADING SPRING 43671 123 ADJUSTING SCREW G5 45903 124 O-RING5/8X3/4 URETH 56020162 125 1/16 FLUSH PLUG W/ SEALA 40049 627 PLATE-BOTTOM 68849 128 GEAR SET 3/8" CLYDESDALE 68855S 129 SHAFT-IDLER 68850 130 SCREEN 68921 131 TUBE-GUIDE .22 68922 232 SHCS 1/4-28 X 1 3/4 68255 533 PLATE-SCREEN MTG. 68927 134 MALE ELBOW 1/8 PIPE 69354 135 SPRING 68225 236 ROLL PIN 1/8 X 3/4 LONG 97782 137 BALL STOP G5 45904 238 GASKET 29/64 X 5/8 86269 239 SPRING CAP UNLOADING VAL 43673 141 TUBE RETURN 68569 143 BEARING ROLLER 1 1/4x1 1 66030 144 BEARING ROLLER 1/2x11/16 68891 345 RING-RETAINING 68892 146 1/8 FLUSH PLUG W/SEALANT 46508 147 CART REL. VAL. ASSEMBLY 66220SS 148 SHAFT SEAL G5 45930 149 PISTON BLOCK ASM G-SERIE SEE PAGE 9 250 SOCKET HEAD CAPSCREW 69392 851 SPRING 68498 152 LEVER-DUMP 68494 153 NUT- 10-32 SELF LOCKING 5757040 154 SET SCREW #10-32 X 1.0 O 68543 155 POW""R BUD DUMP PIN 43344 156 O-RING 7/16x916 5602013 157 DUMP PISTON SEAL 45860 158 DUMP PISTON G5 45906 159 SPRING 68893 160 BALL 3/16" 90548 161 CONE, DUMP 68491 18

G4 Series ElectricPower PumpSub ComponentAssemblies(45533SS) PISTON BLK ASM.1TORQUE TO 400 IN*LBS.1011127425632TORQUE TO25 IN*LBS.TORQUE TO150 IN*LBS.ITEM # DESCRIPTIONPART # QTY.001 PISTON BLOCK G3 45539 1.00002 BALL 1/8" 90906 2.00003 SPRING 66042 1.00004 BALL STOP 68810 1.00005 BALL RETAINER 66043 1.00006 INTAKE SEAT 66046 1.00007 GASKET 25/64X19/32 85726 1.00008 PLUG PISTON BLOCK 68825 1.00009 GASKET 29/64 X 5/8 86269 1.00010 ADAPTER-.290 PISTON 68820 1.00011 SPRING, PISTON 68340 1.00012 PISTON-.290 DIA 68819 1.00TORQUE TO 200 IN*LBS.89(46745SS) ECCENTRIC SHAFT ASM.153254ITEM # DESCRIPTIONPART # QTY.001 ECCENTRIC SHAFT 7/8" 46703 1.00002 ECCENTRIC RING G5 45907 1.00003 ROLL BEARI 1 1/8x1 3/8x3/4 WIDE 45926 1.00004 RETAINING RING EXTERNAL 1 1/8" 45931 1.00005 THRUST WASHER 1 1/8" ID COAT 68026C 2.00(43766SS) UNLOADING PISTON ASM.42 3 1ITEM # DESCRITPIONPART # QTY.01 UNLOAD PISTON 43765 1.0002 O RING 1/4X3/8 5602009 1.0003 BACK-UP WASHER TEF 43768 1.0004 DOWEL PIN 1/8X3/4 LG 43686 1.009

G4 Series ElectricPower PumpValve AssemblyPART#43540SS (DUMP ASM)2TORQUE TO50 IN*LBS.109345SECTION A-A876TORQUE TO150 IN*LBS.11121TORQUE TO180 IN*LBS.AAITEM # DESCRIPTION PART # QTY.1 DUMP VALVE FINISHED 43536P 12 DUMP VALVE PISTON 43537 13 BACKUP WASH TEF -010 43927 14 O RING 1/4X3/8 5602010 15 COMPRESSION SPRING 68871 16 PLUG SAE #6 PORT 68115 17 DUMP VALVE SPACER 43539 18 DUMP VALVE CONE 2 WY 44740 19 SAE #3 SOC. PLUG 43564 110 DUMP VALVE SPRING 43541 111 F9 ELBOW 3/8 90 DEGR STRT 18109 112 PIPE PLUG 46510 1PART#43567SS (2 WAY DUMP ASM)2NOTE:316TORQUE TO 125IN*LBS.10 84 5SECTION A-APOSITION HANDLE SO THAT VALVE ISCLOSED IN POSITION SHOWN.9177414312613TORQUE TO 150IN*LBS.11115TORQUE TO 180IN*LBS.AAITEM # DESCRIPTION PART # QTY.1 DUMP VALVE FINISHED 43536P 12 DUMP VALVE PISTON 43537 13 BACKUP WASH TEF -010 43927 24 O RING 1/4X3/8 5602010 25 COMPRESSION SPRING 68871 16 ADAPTER 68910 17 VALVE STEM 2 WAY 68911 18 BALL 7/32DIA. 96006 19 DUMP VALVE PLUG 46067 110 SPRING 2 WAY VALVE 46068 111 F9 ELBOW 3/8 90 DEGR STRT 18109 112 O-RING SAE PORT #6 5603906 113 FHMS 10-32X.50LG 97156 114 LEVER P6012 115 PIPE PLUG 46510 116 O-RING SAE PORT #3 5603903 117 SPACER 2 WAY VALVE 46069 110

G4 Series ElectricPower PumpValve Sub Assembly(69094SS) 2 WAY MANUAL(69101SS) 4 WAY MANUAL(69691SS) 3 WAY MANUALPART#ITEM # DESCRIPTION2 WAY VAL. QTY.01 2 WAY VALVE 69092 1.0002 BALL 91701 1.0003 VALVE STEM 69095 1.0004 O-RING 5602111 1.0005 BACKUP WASHER 5608111 1.0006 SCREW 44595 1.0007 VALVE HANDLE 69091 1.0008 ROLL PIN 93835 2.0009 SEAT - EXT RELIEF ++ 1.0010 CONE - EXT RELIEF ++ 1.0011 SPRING - RELIEF VALVE ++ 1.0012 ACORN NUT 69105 1.0013 WASHER 69124 1.0014 ADJUSTING SCREW 69104 1.0015 ADAPTER ASSY. 68963 1.0016 SPRING 68384 1.00NS PIPE PLUG 84084 1.0018 1/4 SOC PIPE PLUG 93950 1.0019 HEX ST. PIPE PLUG 87145 1.0020 SPRING CAP 69634 1.0021 LOCKWASHER Y0010765 1.00NS = NOT SHOWNRELIEF REPLACEMENT KIT( ++ = COMPONENTS) -- PART #55057-69691 -69101ITEM # DESCRIPTION3 WAY VAL QTY. 4 WAY VAL QTY.01 VALVE ROTOR 43762 1.00 43762 1.002 O-RING * 2.00 * 4.0003 SUBPLATE- VALVE 68180 1.00 68180 1.0004 O-RING * 1.00 * 1.0005 THRUST WASHER 68026 2.00 68026 2.0006 THRUST BEARING 68155 1.00 68155 1.0007 O-RING * 1.00 * 1.0008 UPPER VALVE BLOCK 69135 1.00 69135 1.0009 DRIVE LOK PIN 93804 1.00 93804 1.0010 O-RING * 6.00 * 3.0011 WASHER * 4.00 * 3.0012 SHEAR SEAL 68029 3.00 68029 1.0013 SPRING WASHER 68028 4.00 68028 3.0014 DETENT SPRING 68025 1.00 68025 1.0015 BALL 92549 1.00 92549 1.0016 VALVE HANDLE 69091 1.00 69091 1.0017 SCREW 44595 1.00 44595 1.0018 SCREW 85317 2.00 85317 2.00NS SCREW 93598 4.00 93598 4.0020 O-RING * 1.00 * 1.0021 SHEAR SEAL 68181 1.00 68181 2.0022 LOCKWASHER Y0010765 1.00 Y0010765 1.00PACKING KIT 3 & 4 WAY MANUAL VALVE( * = COMPONENTS) -- PART # 54490 11

G4 Series ElectricPower PumpValve Sub Assemblies(46285SS) 4 WAY SOLENOID VALVE15TORQUE TO50 IN*LBS.11141234TORQUE TO75 IN*LBS.33 34351034 33352627298671TORQUE TO25 IN*LBS.TORQUE TO100 IN*LBS.323117ITEM # DESCRIPTION PART# QTY1 BODY-VALVE 68708 12 SLIDER TANDEM CENTER 68709 13 3/16" DIA. BALL REF WM581649 90548 14 SET SCREW 1/4-28 X 1/4 CUP 40254 16 O RING REF M792041 * 37 BACK UP WASHER * 38 SHEAR SEAL 68383 39 SPRING 68384 310 O-RING 2 5/8 X 2 3/4 * 111 BEARING ROLLER 5/16x1/2x5/16 WIDE 68385 412 PIN BEARING 68390 213 SET SCREW 5/16-18 X 1/4 CUP 94418 114 SHCS #10-32 X 1"" LG PLATED 68264 215 VALVE TOP PLATE MACHINED 46272 116 1/4" DIA. BALL 92549 117 O-RING (.19x.31x.06)BUNA * 126 O RING * 227 SPRING 68711 231 O-RING 5/16X7/16 URE * 4+ 32 PUSHER-SOLENOID 68729SS 233 RETAINER ++ 234 O-RING ++ 235 PUSHER PIN ++ 21613TORQUE TO75 IN*LBS.* PACKING KIT 4 WAY SOLENOID VALVE 54491+ PUSHER-SOLENOID CONTAINS SPOOL ASSEMBLY, RETAINER, O-RING & PUSHER PIN++ PUSHER REPAIR KIT 68729RKCONTAINS 1 EACH OF RETAINER, O-RING & PUSHER PIN12

G4 Series ElectricPower PumpManifold Sub Assemblies(69570SS) 3 WAY STANDARDPART#PART#ITEM# DESCRIPTION 3 WAY MAN. ASM QTY. ITEM# DESCRIPTION 3 WAY MAN. ASM QTY.01 RET. VALVE MANIFOLD 69569 1.00 NS PIPE PLUG 84084 3.0002 NOZZLE-VALVE 68197 1.00 08 PIPE PLUG-FLUSH 40049 2.0003 SEAT - EXT RELIEF * 1.00 09 O-RING 5602014 1.0004 CONE - EXT RELIEF * 1.00 10 WASHER 69124 1.0005 SPRING - RELIEF VALVE * 1.00 11 ACORN NUT 69105 1.006 ADJUSTING SCREW 69104 1.00 NS = NOT SHOWNRELIEF REPLACEMENT KIT (* = COMPONENTS) -- PART # 55057(69100SS) 4 WAY STANDARDPART#PART#ITEM# DESCRIPTION 4 WAY MAN. ASM QTY. ITEM# DESCRIPTION 4 WAY MAN. ASM QTY.01 VALVE MANIFOLD 69099 1.00 05 SPRING - RELIEF VALVE *1.0002 ADJUSTING SCREW 69104 1.00 06 CONE - EXT RELIEF *1.0003 ACORN NUT 69105 1.00 07 SEAT - EXT RELIEF *1.004 WASHER 69124 1.00 08 PIPE PLUG 84084 2.00RELIEF REPLACEMENT KIT (* = COMPONENTS) -- PART # 5505713

G4 Series ElectricPower PumpManifold Sub Assemblies(68581SS) 4 WAY LOCKINGPART # PART #ITEM # DESCRIPTION 3 WAY LOCK QTY. ITEM # DESCRIPTION 4 WAY LOCK QTY.01 VALVE BODY LOCK VAL 68591 1.00 10 SPRING - RELIEF VALVE ++ 1.0002 BALL 92549 1.00 11 CONE - EXT RELIEF ++ 1.0003 RELEASE GLAND 68637 1.00 12 SEAT - EXT RELIEF ++ 1.0004 O-RING * 1.00 13 BU-WASHER * 2.0005 RELEASE SCREW ASM 89435 1.00 14 BALL RETAINER 68589 2.0006 O-RING * 1.00 15 O-RING 5602106 1.0007 BALL 92526 2.00 16 SPOOL-LOCK VALVE 68636 1.0008 O RING * 1.00 17 SEAT 68590 2.0009 RELIEF VALVE ADJ SCREW 66083 1.00 18 PIPE PLUG 82552 1.00RELIEF REPLACEMENT KIT (++ = COMPONENTS) -- PART # 55057PACKING KIT 3 & 4 WAY LOCK VALVE (* = COMPONENTS) -- PART #54492(69621SS) 3 WAY LOCKINGPART#PART#ITEM# DESCRIPTION 3 WAY LOCK QTY. ITEM# DESCRIPTION 4 WAY LOCK QTY.01 VLV BODY LOCKING 69573 1.00 13 GASKET-PLUG 68183 1.0002 SEAT - EXT RELIEF ++ 1.00 14 PLUG-SPOOL 68184 1.0003 CONE - EXT RELIEF ++ 1.00 15 BALL 92550 1.0004 SPRING - RELIEF VALVE ++ 1.00 16 GASKET WASHER 68080 1.0005 SCREW 69104 1.00 17 PORT ADAPTER 68187 1.0006 WASHER 69124 1.00 18 ACORN NUT 69105 1.0007 RETAINING SLEEVE 69620 1.00 19 NOZZLE-VALVE 68197 1.0008 O RING * 1.00 20 PIPE PLUG 3/8" 84084 2.0009 BACK-UP WASHER * 1.00 21 PIPE PLUG 1/8" 81093 3.0010 O-RING * 1.00 NS 1/16 PIPE PLUG- 40049 2.0011 HEX ST. PIPE PLUG 87145 1.00 23 COMPRESSION SPRING 68188 1.0012 SPOOL 69574 1.00 24 LOCTITE 41828 0.10PACKING KIT 3 & 4 WAY LOCK VALVE (* = COMPONENTS) -- PART #54492RELIEF REPLACEMENT KIT (++ = COMPONENTS) -- PART # 5505714

ONJ1ONJ1G4 Series ElectricPower PumpControl Box Assemblies(46737SS) Control Box 115 V.1TORQUE TO4.3 IN*LBSTORQUE TO150 IN*LBS1415SIMPLEX1-800-323-9114www.tksimplex.comPart # 46196Rev. A220/240V1 2 3 4110/120VAC+ COM COM SW ADV COM RETBLUEBROWNBROWNGREENYELLOW1625"6GREEN/YELLOWBLUEBROWN11911 12 8"2MOVE SELECTORTO 110/120VTORQUE TO1315 IN*LBS3220/240V110/120V17SIMPLEX1-800-323-9114www.tksimplex.comPart # 46196Rev. AAC+ COM COM SW ADV COM RET1 2 3 44545TORQUE TO25 IN*LBS78 10TORQUE TO15 IN*LBSITEM # DESCRIPTION PART # QTY.001 CONTROL BOX MACH G4 PUMPS 46736 1.00002 PLUG AND CORD ASSY 68595 1.00003 CIRCUIT BOARD BASIC 46196 1.00004 FITTING,CORD L-TIGHT 68375 2.00005 LOCKNUT 1/2 INCH 85510 2.00006 RING TERMINAL 1/4" 69917 1.00007 SHCS #10-32X1/4" LG PLATED 45175 1.00008 FUSE HOLDER 30 AMP 46481 1.00009 FUSE 25 AMP 46482 1.00010 SHCS #6-32 x 1/4 LONG 46506 1.00011 SPADE TERMINAL 68116 2.00012 HOOK UP WIRE 14 GA BROWN 46676 0.67013 MACHINE SCREW W/ LOCK WASHER #6-32 46248 5.00014 HHCS 5/16-18 X 1.0 95059 4.00015 HEX NUT 5/16-18 ZINC PLTD Y0001045 4.00016 POWER CORD 14-3 IEC 69604R 2.08315

ONJ1ONJ1G4 Series ElectricPower PumpControl Box Assemblies(46738SS) Control Box 230 V.1TORQUE TO4.3 IN*LBSTORQUE TO150 IN*LBS1415SIMPLEX1-800-323-9114www.tksimplex.comPart # 46196Rev. A220/240V1 2 3 4110/120VAC+ COM COM SW ADV COM RETBLUEBROWNBROWNGREENYELLOW1625"6GREEN/YELLOWBLUEBROWN11911 12 8"MOVE SELECTORTO 220/240VTORQUE TO1315 IN*LBS1716 72"23SIMPLEX1-800-323-9114www.tksimplex.comPart # 46196Rev. A220/240V110/120VAC+ COM COM SW ADV COM RET1 2 3 44545TORQUE TO25 IN*LBS78 10TORQUE TO15 IN*LBSITEM # DESCRIPTION PART # QTY.001 CONTROL BOX MACH G4 PUMPS 46736 1.00002 PLUG 20 AMPS-250V 87093 1.00003 CIRCUIT BOARD BASIC 46196 1.00004 FITTING,CORD L-TIGHT 68375 2.00005 LOCKNUT 1/2 INCH 85510 2.00006 RING TERMINAL 1/4" 69917 1.00007 SHCS #10-32X1/4" LG PLATED 45175 1.00008 FUSE HOLDER 30 AMP 46481 1.00009 FUSE 12 AMP 46739 1.00010 SHCS #6-32 x 1/4 LONG 46506 1.00011 SPADE TERMINAL 68116 2.00012 HOOK UP WIRE 14 GA BROWN 46676 0.67013 MACHINE SCREW W/ LOCK WASHER #6-32 46248 5.00014 HHCS 5/16-18 X 1.0 95059 4.00015 HEX NUT 5/16-18 ZINC PLTD Y0001045 4.00016 POWER CORD 14-3 IEC 69604R 8.08316

ONONG4 Series ElectricPower PumpWire ConfigurationsMOTOR CONTROLWIRING DIAGRAM 115V.SET DIP SWITCHESAS SHOWNCONNECT 46246 MEMBRANESWITCH HERE ALIGNING THEARROWS.1 2 3 4ONSWITCH TO BEIN 110/120VPOSITION2,4,81,3,5E.M110/120V220/240VSIMPLEX1-800-323-9114www.tksimplex.comPart # 46196Rev. AJ11 2 3 4AC+ COM COM SW ADV COM RETBLUEBROWNBROWNGREENYELLOWORANGEGREENBLUEBROWNGREEN/YELLOWBLUEBROWNMOTOR CONTROLWIRING DIAGRAM 230V.SET DIP SWITCHESAS SHOWNCONNECT 46246 MEMBRANESWITCH HERE ALIGNING THEARROWS.1 2 3 4ONSWITCH TO BEIN 220/240VPOSITION4,81E.M2,3,5110/120V220/240VSIMPLEX1-800-323-9114www.tksimplex.comPart # 46196Rev. AJ11 2 3 4AC+ COM COM SW ADV COM RETBLUEBROWNBROWNGREENYELLOWORANGEGREENBLUEBROWNGREEN/YELLOWBLUEBROWN17

ONJ1ONG4 Series ElectricPower PumpWire ConfigurationsSOLENOID CONTROLWIRING DIAGRAM 115V.SET DIP SWITCHESAS SHOWN1 2 3 4TORQUE TO3.5 IN*LBSPENDANTONSIMPLEX1-800-323-9114www.tksimplex.comPart # 46196Rev. ASWITCH TO BEIN 110/120VPOSITION220/240V1 2 3 4110/120VAC+ COM COM SW ADV COM RETBLUEBROWNGREENYELLOW2,4,81,3,5BLUEBROWNE.MADVRETCORD 30" LONGBLUEBROWNCUT OFF GREEN/YELLOWWIRE AT END OFINSULATIONORANGEGREENBLUEBROWNBROWNGREEN/YELLOWBLUEBROWNCUT OFF GREEN/YELLOW WIREAT END OF INSULATIONSOLENOID CONTROLWIRING DIAGRAM 230V.SET DIP SWITCHESAS SHOWN1 2 3 4PENDANTONSIMPLEX1-800-323-9114www.tksimplex.comPart # 46196Rev. ASWITCH TO BEIN 220/240VPOSITIONJ1220/240V1 2 3 4110/120VAC+ COM COM SW ADV COM RETBLUEBROWNGREENYELLOW4,81BLUEBROWNE.MADV2,3,538RETCORD 30" LONGCUT OFF GREEN/YELLOWWIRE AT END OFINSULATIONBLUEBROWNORANGEGREENBLUEBROWNBROWNGREEN/YELLOWBLUEBROWNCUT OFF GREEN/YELLOW WIREAT END OF INSULATION18

G4 Series ElectricPower PumpReservoirs(45996P) 1.5 GALLON RESERVIOR(46213P) 2.5 GALLON RESERVIOR(46046P) 5.0 GALLON RESERVIOR(46048P) 10 GALLON RESERVIOR(DS1256025) 20 GALLON RESERVIOR5748973352Series11/2hp1,1 Kw46052610NOTE: THIS ILLUSTRATION IS FOR REFERENCE ONLY.THE APPEARANCE OF YOUR UNIT MAY DIFFERFROM UNIT SHOWN.ITEM # DESCRIPTION 1.5 GALLON 2.5 GALLON 5.0 GALLON 10 GALLON 20 GALLON QTY.03 RESERVOIR 45996P 46213P 46046P 46048P DS1256025 1.0004 RESERVOIR GASKET 8546985469 85469 85469 85469 1.0005 BREATHER VENT 3/8" NPT 4634846348 46348 46348 46348 1.0006 PLUG 4669746697 46697 46697 46697 1.0007 SAE #12 HEX PLUG WITH PORT 4611846118 46118 46118 46118 1.0008 HHCS 1/4-20 x 3/4 LG PLATED 6589165891 65891 65891 65891 14.0009 SEALING WASHER 6589265892 65892 65892 65892 14.0010 G4 RESERVOIR DECAL 46635 46635 46635 46635 46635 2.0052 SIGHT GAUGE 4600946009 46009 46009 46009 1.0073 COVER PLATE 45905 45905 45905 45905 45905 1.00NS PIPE COUPLING 1/4 N/AN/AN/A 80241 80241 1.00NS NIPPLE N/AN/AN/A 88058 88058 1.00NS = NOT SHOWNNOTE: ALL RESERVOIRS ARE POWDER COATED BLACK19

Once you have selected your cylinder. find the required reservoir capacity in the cylinder specification chart. and choose a hand pump with at least 10% more reservoir capacity per cylinder.

An R256 cylinder (page 11) has a required oil capacity of 527.6 cm3. The P42 hand pump (page 34) with a reservoir capacity of 737.4 cm3 can pump this cylinder to its full stroke. If two R256 cylinders are to be raised. use a P140 with a reservoir capacity of 2867.7 cm3 6.35 mm I.D. hose requires 32.2 cm3 oil per meter. 9.65 mm I.D. hose requires 69.9 cm3 per meter.

Once you have selected your cylinder. find the required reservoir capacity in the cylinder specification chart. and choose a hand pump with at least 10% more reservoir capacity per cylinder.

As the new member of the Hydro product range, the hydraulic diaphragm metering pump Hydro/ 2 API 675 (HA2a) meets the requirements of API 675. The pumps stand ...

The key task of electro-hydraulic pumps is to convert electric energy (current and voltage) into hydraulic energy (flow and pressure). To reduce heat loss, Rexroth external ...

... control options provide the flexibility to match the pump to a wide range of pressing, punching and other operations. Compare the ZE2 to the other pumps in the ZE-Series and determine the best pump ...

... options: direct manual, servo-assisted manual, remote hydraulic, remote hydraulic with feedback, On-Off electric in closed centre and open centre configurations, proportional electric and hydraulic ...

Sophisticated technology in the smallest space - this is what our Alfra electro-hydraulic pumps stand for. Due to the compact design, the powerful drive units also find room when things ...

... our ALFRA hydraulic cylinder SKP-1. In a team with the hydraulic pump DSP-120 it is capable to take a variety of challenges – because the SKP-1 working with a maximum operating pressure ...

... devices. With a pressure of 700 bar and a maximum flow rate of 0.58 liters per minute, the electro-hydraulic pump is a strong partner - for example for our hydraulic cylinders for punching ...

... alkitronic hydraulic pumps with electric or pneumatic drive provide fast operating speed, reliability, and safety. They are designed for permanent operation. Our hydraulic ...

... pneumatic or electric operation for both single acting and double acting cylinders. A wide range of accessories is also available. Electric and Air Hydraulic Pumps.

Compact, Portable, Cordless Hydraulic Pump for MRO Applications. Compact, Li-ion 18VDC, 9.0 Ah battery-powered pump provides extended run-time. Two-stage, ...

The 10 series Power Team hydraulic pumps are designed to have a maximum of 690 bar (10,000 psi) at a flow rate of 164 cc/min (10 cu. in/min). All Power Team pumps come fully assembled, ...

The Power Team 30 series pump is intently ideal for maintenance and construction applications. Operating both single-acting or double-acting cylinders. A dynamically built, Integral roll cage protects the 30 series pump ...

Practical and functional, the BDP700-5L hydraulic pump is powered by a lithium battery with a slide connection, which guarantees maximum efficiency and a long life

Practical and functional, the BDP700-1L hydraulic pump is powered by a lithium battery with a slide connection, which guarantees maximum efficiency and a long life

... complex units. The pumps lift weights of up to 800 kg – quietly, steplessly and completely in sync. They are powered by an electric drive unit or hand crank.

Bucher Hydraulics electro-pumps series ET are equipped with modern external gear pumps - AP05, AP100 and AP212 series together with efficient DC or AC electro-motors. These electro-pumps ...

The pump series Eco-MAX developed by ITH is built for standard applications like service and assembly jobs. The pump series is available in two different designs:

Get a range of wholesale simplex manual hydraulic test pump designed for different testing needs. For those involved in the field of digital electronics and who need to work with digital circuits and systems regularly, consider the wide range of logic analyzers that are available. Quality testing equipment will be able to help verify and debug your digital designs efficiently when required.

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