G3 SERIES TORQUE POWER PUMP PARTS IDENTIFICATION MANUAL Reference # - TD056 Rev. - D Date - 1/14

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1 Oakmont Lane, Westmont, IL Outside U.S G SERIES TORQUE POWER PUMP PARTS IDENTIFICATI MANUAL Reference # - TD0 Rev. - D Date - / This illustration is for reference purposes only. The appearance of your unit may differ from the unit shown. Electrical Brackets Wiring Diagrams - pg. - Valve Sub-Assemblies - pg. Pendants - pg. - Manifold Sub-Assembly - pg. SIMPLEX Common Components used in all G Series pumps - pg. - Pump Sub-Assemblies and Sub-Components - pg. - Series G hp / 0, Kw Reservoirs 0 - pg.

2 G Torque Wrench How to Identify Parts for Your Model. MODEL MATRIX Understanding our model number configurations: PUMP CLASS Sample Model #: G T Z R Description: PUMP TYPE Model Performance Series Power Consumption Valve Function Reservoir Size G = Gen II Pump =. HP = V = 0 V = Torque Wrench = Gal =. Gal =. Gal OPTI OPTI Options T = Torque Wrench C = Caster Wheel Kit OPTI R = Roll Cage Z = Mutli-port (torque) MODEL NUMBER & DATE CODE LOCATI DATE CODE COVER PLATE STAMPING LOCATI SIMPLEX MODEL DECAL PLEMENT Series G hp / 0, Kw 0

3 SKIN PUNCTURE/ HYDRAULIC LINE BEFORE OPERATING PUMP:. Be sure the electrical connection is grounded. REVIEW ALL OPERATING INSTRUCTIS. Check that your power supply agrees with the motor nameplate.. Use only equipment rated for,000 PSI / 00 BAR.. Make sure all connections are tight, secure and kink-free.. Check the reservoir oil level. Fill to one inch of the top, if necessary.,000 PSI/ 00 BAR. Never operate the pump without tool movement for more than minute without shifting the control valve to neutral. Leaving the tool in the advance or retract position without tool movement may overheat the oil. Do not exceed oil operating temperatures of 0 F or 0 C. AFTER COMPLETING THE JOB:. Before disconnecting your equipment, first be sure the tool is unloaded, then unplug the power cord and shift the hydraulic controls several times to release system pressure.. Store the pump in a clean, dry place. PERIODIC MAINTENANCE:. Change the hydraulic oil and clean the oil screen, breather and magnet (located in the reservoir) twice a year. Refer to the operating instructions for details. When used in extremely dusty areas or oil has been overheated, change the oil more frequently. 0 R 0 G Series Electric Common components used in pumps NOTE: This illustration is for reference only. The appearance of your unit may differ from unit shown. INSTALL SHIPPING PLUG AND SHIP BREATHER VENT IN A BAG FOR CUSTOMER TO INSTALL 0 IN*LBS 0 IN*LBS 0 IN*LBS 0 0 IN*LBS Power Control Center ADVANCE I I OFF PENDANT FUNCTI In event multiple buttons are depressed for seconds, the power pump will shutdown. TO RESTART PUMP Press the On button to restart. If problem persists, unplug the line cord from outlet to reset. 0 IN*LBS 0 IN*LBS 0 IN*LBS 0 IN*LBS ELECTRIC PUMP INSTRUCTIS FOR SAFE OPERATI 0 0 IN*LBS SIMPLEX 0 IN*LBS Series G / hp 0, Kw 0 0 IN*LBS 0

4 G Series Electric Common components used in pumps ITEM # DESCRIPTI V. 0 V. QTY. ITEM # DESCRIPTI V. 0 V. QTY. 0 PUMP ASSEMBLY SEE PAGE BHCS - x / LG.00 0 RESERVOIR BLK SEE PAGE.00 SIMPLEX DECAL." x.".00 0 RESERVOIR GASKET *.00 BRKET SUPPORT G.00 0 BREATHER VENT /" NPT.00 HOLE PLUG /" PIPE PLUG /" W/ COATING.00 SPER." LG SAE # HEX PLUG WITH PORT.00 HHCS /-0 X HHCS /-0 X. PLT.00 WASHER /" SS.00 0 SEALING WASHER.00 COIL WITH DIN CNECTOR.00 G RESERVOIR DECAL SIGHT GAUGE LABEL SAFE USE ELEC MEMBRANE SWITCH DECAL ++ BLANK DECAL X DECAL PENDANT INSTRUCT. ++ MANIFOLD ASM. SEE PAGE.00 SIMPLEX DECAL." x." ++ VALVE GASKET.00 / IN NIPPLE SHCS /- X /.00 /" NIPPLE CT CT.00 ADAPTER ASSY..00 /" SELF-LOCKING COUPLER.00 HEX PIPE PLUG /" COATING.00 GAUGE SHROUD ASM.00 VALVE ASM. P/W SEE PAGE.00 BHCS - X SHCS /- X /.00 GAUGE SHROUD MOUNTING PLATE.00 LOCK WASHER /.00 VELCRO STRAP x.00 ROLL PIN / X / LG MOTOR GASKET *.00 MAGNET GASKET POW'R PUMP *.00 MOTOR SHROUD W/ HANDLE.00 COVER PLATE SEE PAGE.00 HOSE CLAMP.00 SHCS #- X /".00 DECAL OVERLAY.00 SHCS #- X " LG.00 BRKET ASM G PET SEE PAGE -.00 G MOTOR.HP V.00 HEAVY HEX JAM NUT /-0.00 FHCS - X 0.0LG.00 SHCS #- X FOAM INSERT.00 G SERIES PENDANT DECAL KIT (+ + = COMPENTS) -- PART # G REBUILD KIT ( * = COMPENTS) -- PART #

5 G Series Electric Pump Assembly (SS) PUMP ASM. ITEM # DESCRIPTI PART # QTY. 0 GEAR SECTI ASSEMBLY SEE PAGE PUMP VALVE SECTI ASSEMBLY SEE PAGE.00 0 SHCS /- X " LG.00 0 PIST BLOCK TUBE G.00

6 G Series Electric Gear Section Assembly (SS) GEAR SECTI ASM. SECTI A-A IN*LBS A A 0 IN*LBS 0 IN*LBS 0 IN*LBS 0 TORQUE ALL /- BOLTS TO IN*LBS.

7 G Series Electric Gear Section Assembly (SS) GEAR SECTI ASM. ITEM # DESCRIPTI PART # QTY. 0 G PUMP BODY PIST.00 0 TUBE-GUIDE SHCS /- X /.00 0 SET SCREW #- X / CUP.00 0 O-RING /X/ *.00 0 SHCS /- X.LG 0.00 POW'R BUD REDUC GEAR 0.00 POW'R BUDDY PUMP SHAFT.00 ROLL BRG /ID X /.00 POW'R BUD ECC RING.00 ROLL BRG / X /.00 BEARING ROLLER /x/x/ WIDE.00 O RING /X/ *.00 GEAR-SET G DS.00 BALL /" BEARING ROLLER /x/x/ WIDE BOTTOM PLATE /" GEARS G.00 POW'R BUDDY ECCENCTRIC RING.00 THRUST WASHER /"ID.00 THRUST BRG /" ID.00 POW'R BUDDY IDLER SHAFT.00 RING-RETAINING.00 WASHER /" SS.00 POW'R BUDDY SCREEN *.00 O-RING /X/ *.00 0 PIST BLOCK ASSEMBLY # G SEE PAGE.00 PIST BLOCK ASSEMBLY G SEE PAGE.00 SHCS /- X..00 BALL /" 0.00 G PIST BLOCK TUBE 0.00 O-RING /X/ *.00 MALE TEE.00 G REBUILD KIT (* = COMPENTS) -- PART #

8 G Series Electric Pump Valve Section Assembly (0SS) PUMP VALVE SECT ASM. 0 0 IN*LBS. IN*LBS. 0 IN*LBS. SECTI B-B B SECTI A-A 0 IN*LBS. B A A ITEM # DESCRIPTI PART # QTY. 0 PB VALVE BODY SECT BALL /" SPRING.00 0 GASKET /X/ *.00 0 SCREW, BALL STOP.00 0 MALE ELBOW / PIPE.00 0 UNLOADING PIST ASM PAGE.00 0 BALL /".00 SPRING UNLOADING VLV.00 O-RING /X/ *.00 ADJUSTING SCREW.00 / SOC PIPE PLUG.00 / SOC PIPE PLUG.00 SEAT - EXT RELIEF CE - EXT RELIEF SPRING - RELIEF VALVE ROLL PIN /X/.00 G REBUILD KIT (* = COMPENTS) -- PART # RELIEF REPLEMENT KIT ( ++ = COMPENTS) -- PART #0

9 G Series Electric Sub Component Assemblies (SS) PIST BLK ASM. 00 IN*LBS. 00 IN*LBS. IN*LBS. 0 IN*LBS. ITEM # DESCRITPI PART # QTY. 0 GEN II PIST BLOCK.00 0 BALL /" SPRING BALL STOP.00 0 BALL RETAINER INTAKE SEAT GASKET / X / *.00 0 PLUG PIST BLOCK.00 0 GASKET /X/ *.00 ADAPTER-.0 PIST 0.00 SPRING, PIST 0.00 PIST-.0 DIA.00 (SS) PIST BLK ASM. 00 IN*LBS. 00 IN*LBS. MIN. 0 IN*LBS. IN*LBS. 0 IN*LBS. ITEM # DESCRIPTI PART # QTY. 0 PIST BLOCK.00 0 BALL /" SPRING BALL STOP.00 0 BALL RETAINER INTAKE SEAT GASKET / X / *.00 0 PLUG PIST BLOCK.00 0 GASKET /X/ *.00 ADAPTER-.0 PIST 0.00 SPRING, PIST 0.00 PIST 0.0" DIA..00 MALE ELBOW / PIPE.00 (SS) UNLOADING PIST ASM. ITEM # DESCRITPI PART # QTY. 0 UNLOAD PIST O RING /X/ *.00 0 BK-UP WASHER.00 0 DOWEL PIN /X/ LG.00 G REBUILD KIT ( *= COMPENTS) -- PART #

10 G Series Electric Valve Sub Assemblies (SS) SOLENOID VALVE V. / 0V. PLES 0 IN*LBS. IN*LBS. PLES 0 IN*LBS. 0 IN*LBS. IN*LBS. ITEM# DESCRIPTI PART# QTY. BODY-VALVE 0 SLIDER TANDEM CENTER 0 /" DIA. BALL REF WM 0 SET SCREW /- X / CUP 0 O RING REF M0 * BK UP WASHER * SHEAR SEAL SPRING O-RING / X / 00 BEARING ROLLER /x/x/ WIDE PIN BEARING 0 SET SCREW /- X / CUP SHCS #- X "" LG PLATED VALVE TOP PLATE MHINED /" DIA. BALL O-RING (.x.x.0)buna * VALVE PLUG POSITI SLIDER O RING * SPRING O-RING /X/ URE * + PUSHER-SOLENOID SS RETAINER ++ O-RING ++ PUSHER PIN ++ - IN*LBS. * PKING KIT WAY SOLENOID VALVE + PUSHER SOLENOID CTAINS SPOOL ASSEMBLY, RETAINER, O-RING & PUSHER PIN ++ PUSHER REPAIR KIT RK CTAINS EH OF RETAINER, O-RING & PUSHER PIN

11 G Series Electric Manifold Assembly (SS) MANIFOLD ASM. - FT.LBS - FT.LBS - FT.LBS - FT.LBS - FT.LBS - FT.LBS - FT.LBS - FT.LBS - FT.LBS - FT.LBS ITEM # DESCRIPTI PART # QTY. 0 VALVE MANIFOLD CARTRIDGE RELIEF VALVE.00 0 / PIPE PLUG-FLUSH PIPE PLUG /" FLUSH.00 0 PIPE NIPPLE / NPT.00 0 PIPE COUPLING /.00 0 INT.RELIEF ASM HF SS.00 (SS) INT. RELIEF ASM. ITEM # DESCRIPTI PART # QTY. 0 CARTRIDGE CE REL VLVE POPPET RELIEF SPRING.00 0 RELIEF VALVE ADJUSTING SCREW HEX NUT /

12 R G Series Electric Bracket Sub Assemblies (SS) BRKET SUB ASM. V. " BRING VALVE DIN CORD THRU THIS GROMMET PET - +. IN*LBS " 0 ADV CORD LENGTH " BROWN + COM COM SW ADV COM RET Part # Rev. A SIMPLEX IN*LBS /0V 0/0V J PENDANT BROWN BLUE GREEN ORANGE BLUE PENDANT FUNCTI In event multiple buttons are depressed for seconds, the power pump will shutdown. TO RESTART PUMP Press the On button to restart. If problem persists, unplug the line cord from outlet to reset. OFF I I ADVANCE 0 CUT OFF GREEN/YELLOW END OF OUTSIDE INSULATI " BROWN BLUE GREEN/YELLOW IN*LBS IN*LBS - + ASSEMBLED IN HOLE THAT IS LOWER AND TOWARDS THE MIDDLE. IN*LBS MOVE SELECTOR TO /0V /0V 0/0V J BRING WIRE THRU GROMMET IN BRKET + COM COM SW ADV COM RET SIMPLEX Part # Rev. A IN*LBS IN*LBS ITEM # DESCRIPTI PART # QTY. ITEM # DESCRIPTI PART # QTY. 0 MOUNTING BRKET.00 RING TERMINAL /".00 0 PLUG AND CORD ASSY.00 SHCS #-X/" LG PLATED.00 0 CIRCUIT BOARD BASIC.00 GROMMET /" HOLE.00 0 BRIDGE RECTIFIER A.00 PENDANT ASSEMBLY BASIC SHCS #- X / 0.00 MEMBRANE SWITCH LABEL PET *.00 0 FITTING,CORD L-TIGHT.00 0 MOLDED DIN CNECTOR W/ CORD.00 0 LOCKNUT / INCH.00 PUSH THRU BUSHING MHINE SCREW W/ LOCK WASH.00 DECAL PENDANT INSTRUCTI *.00 HOLE PLUG /".00 SIMPLEX DECAL." x 0." *.00 HHCS /-0 X. PLT.00 FUSE HOLDER 0 AMP.00 HEX NUT /-0 PLATD.00 FUSE AMP.00 WIRE # BLK B.00 SHCS #- x / LG 0.00 QUICK DISC. FLAG BLUE.00 SPADE TERMINAL.00 G SERIES PENDANT DECAL KIT (* = COMPENTS) -- PART #

13 R G Series Electric Bracket Sub Assemblies (SS) BRKET SUB ASM. 0V. " BRING VALVE DIN CORD THRU THIS GROMMET PET - +. IN*LBS " 0 ADV CORD LENGTH " BROWN + COM COM SW ADV COM RET Part # Rev. A SIMPLEX IN*LBS /0V 0/0V J PENDANT BROWN BLUE GREEN ORANGE BLUE PENDANT FUNCTI In event multiple buttons are depressed for seconds, the power pump will shutdown. TO RESTART PUMP Press the On button to restart. If problem persists, unplug the line cord from outlet to reset. OFF I I ADVANCE 0 CUT OFF GREEN/YELLOW END OF OUTSIDE INSULATI " BROWN BLUE GREEN/YELLOW IN*LBS IN*LBS - + ASSEMBLED IN HOLE THAT IS LOWER AND TOWARDS THE MIDDLE. IN*LBS MOVE SELECTOR TO 0/0V /0V 0/0V J + COM COM SW ADV COM RET BRING WIRE THRU GROMMET IN BRKET SIMPLEX Part # Rev. A IN*LBS IN*LBS ITEM # DESCRIPTI PART # QTY. ITEM # DESCRIPTI PART # QTY. 0 MOUNTING BRKET.00 RING TERMINAL /".00 0 Cord Assembly 0V SHCS #-X/" LG PLATED.00 DD0.00 US/CAN Lg FT GROMMET /" HOLE.00 0 CIRCUIT BOARD BASIC.00 PENDANT ASSEMBLY BASIC BRIDGE RECTIFIER A.00 MEMBRANE SWITCH LABEL PET *.00 0 SHCS #- X / MOLDED DIN CNECTOR W/ CORD.00 0 FITTING,CORD L-TIGHT.00 PUSH THRU BUSHING LOCKNUT / INCH.00 DECAL PENDANT INSTRUCTI *.00 0 MHINE SCREW W/ LOCK WAS.00 SIMPLEX DECAL." x 0." *.00 HOLE PLUG /".00 FUSE HOLDER 0 AMP.00 HHCS /-0 X. PLT.00 FUSE AMP.00 HEX NUT /-0 PLATD.00 SHCS #- x / LG 0.00 WIRE # BLK B.00 SPADE TERMINAL.00 QUICK DISC. FLAG BLUE.00 G SERIES PENDANT DECAL KIT (* = COMPENTS) -- PART #

14 G Series Electric Reservoirs (P).0 GALL RESERVIOR (P). GALL RESERVIOR (P). GALL RESERVIOR Series G 0 / hp 0, Kw. GALL RESERVOIR NOTE: THIS ILLUSTRATI IS FOR REFERENCE LY. THE APPEARANCE OF YOUR UNIT MAY DIFFER FROM UNIT SHOWN. ITEM # DESCRIPTI.0 GALL QTY.. GALL. GALL QTY. 0 RESERVOIR P.00 P P.00 0 RESERVOIR GASKET BREATHER VENT /" NPT / SOC PIPE PLUG SAE # HEX PLUG WITH PORT N/A HHCS /-0 x / LG PLATED SEALING WASHER G RESERVOIR DECAL SIGHT GAUGE COVER PLATE

15 UNITED STATES HOME OFFICE OAKMT LANE, STE WESTMT, IL 0 PHE: FAX TOLL FREE: sales@tksimplex.com Printed in the U.S.A.

G5 SERIES TORQUE POWER PUMP PARTS IDENTIFICATION MANUAL Reference # - TD058 Rev. - C Date - 1/12

G5 SERIES TORQUE POWER PUMP PARTS IDENTIFICATION MANUAL Reference # - TD058 Rev. - C Date - 1/12 OAKMT LANE, SUITE 00 WESTMT, IL 0. 1.0..0 www x.c G SERIES TORQUE POWER PUMP PARTS IDENTIFICATI MANUAL Reference # - TD0 Rev. - C Date - 1/1 This illustration is for reference purposes only. The appearance