PED SERIES HYDRAULIC & MECHANICAL POWER ELECTRIC DUMP PUMPS. Operating & Maintenance Instructions Electric Dump Pumps.

Transcription

1 PED SERIES HYDRAULIC & MECHANICAL POWER ELECTRIC DUMP PUMPS SERVING INDUSTRY WITH PRIDE SINCE - Templeton Kenly& Co., Inc. QUALITY Operating & Maintenance Instructions Electric Dump Pumps. EQUIPMENT SERVICE ASSOCIATION Part Sheet #: Revised: -00 USA REBUILDERS OF TOOLS & M E M B E R EQUIPMENT CANADA The world's most complete line of industrial, hydraulic and mechanical lifting and positioning equipment. SIMPLEX DIVISION OF TEMPLETON, KENLY & CO., INC. Gardner Road Broadview, Illinois 0 (0) -00 / Fax (0) -0

2 Before Operating Pump: OPERATING INSTRUCTIONS AT A GLANCE. Be sure the electrical connection is grounded. Check that your power supply agrees with the motor nameplate.. Use only cylinders, hoses and equipment rated at 0,000 PSI.. Make sure all hose and fitting connections are tight and secure. Hoses cannot be kinked or twisted.. Oil level should be to " from the top of the reservoir plate, with cylinders retracted and motor off.. Never operate the pump with the directional control valve in advance or retract at 0,000 PSI without ram movement for more than minute. Leaving the valve in the advance or retract position without the rams piston rod moving will overheat the oil. After Completing the Job:. Before disconnecting hoses, fittings, etc., first be sure the ram is retracted & unloaded, then unplug the power cord and shift the hydraulic controls several times to release system pressure.. Store the pump in a clean, dry area. Periodic Maintenance:. 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 # AO, 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 pumps warranty. --

3 SECTION I SAFETY -. Working Pressure The pump's maximum working pressure is 0,000 PSI (00 kg/cm ). Make sure that all hydraulic equipment such as rams, hoses, etc. used with this pump are rated at 0,000 PSI operating pressure. -. Hydraulic Connections Never disconnect or connect any hydraulic hoses or fittings without first unloading the ram, then unplug the electrical cord of the pump and shift, or open all hydraulic controls several times to assure that the system has been depressurized. If the system includes a gauge, 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. *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. CHECK FOR PROPER ELECTRICAL SUPPLY BEFORE CONNECTING.. THIS MOTOR MAY SPARK. DO NOT OPERATE IN AN EXPLOSIVE ATMOSPHERE OR IN THE PRESENCE OF CONDUCTIVE LIQUIDS. a. Do not use a power or extension cord that is damaged or has exposed wiring. b. All single phase motors 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. -. Jacking Safely You must know the weight of what you intend to lift and choose a ram with at least 0% 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. Never crawl or place any part of your body under any load at any time. Insert blocking or cribbing 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 B0.). --

4 SECTION II INSTRUCTIONS BEFORE USE Read carefully. Most malfunctions in new equipment are the result of improper operation and/or improper set-up 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. 0. H.P., V up to 0' - gage -. Hydraulic Connections: Check hydraulic oil level to prevent possible pump burnout. Open the red plastic fill plug located on reservoir plate. Oil level should be approximately " from top of reservoir plate -- with cylinders retracted and motor off. Add Simplex oil as necessary. Do not mix different grades of oil. Make sure all desired gauge, valve, hose and quick coupler connections are tight and secure before operating (See Section.). The pumps pressure ports are / NPTF and are located just below the control valve. (See Section -). The use of a pressure gauge is strongly recommended for normal operation of these pumps and required when the external adjustable relief valve pressures are changed. Mounted on a gauge adapter between the pump and cylinder, the gauge permits the operator to monitor loads on cylinders. Do not exceed rated capacity of equipment connected to pump. Where shock loading or unsteady loads may cause overloading of cylinders, the operator must use larger capacity cylinders to provide additional operating margin. --

5 SECTION III OPERATION -. Control Valves: a. -Way Valve for Single Acting Rams To Advance...turn lever to the right & start motor. To Hold...turn motor off. To Retract...turn lever to the left. * Useable / NPTF port * b. -Way Valve for Single Acting Rams To Advance...push lever to right. For Neutral/Hold...place lever in middle. To Retract...push lever to left. Return ports only. (Marked T) * A * A c. -Way Valve for Double Acting Rams Pushing lever to right directs pump output to right-hand port. Pushing lever to left directs pump output to left-hand port. Center position is neutral/hold. Pump output is directed back to tank. B * B * * A * A -.. Before starting pump, place valve in Neutral/Hold position (as described above) to prevent accidental lifting or moving of load. Start the pump and let the pump idle for a few minutes. -. Bleeding the Hydraulic System--air can be removed from the system by fully advancing and retracting the hydraulic cylinder several times with the pump elevated so its reservoir is higher than the cylinder. Single-acting cylinder should be inverted, and double-acting on their side with the coupling fitting up. When the trapped air is removed from the hydraulic circuit, the cylinder will advance and retract smoothly. Sluggish cylinder action is usually the first sign of air in the system. -. Move lever to Advance position (as described above) to activate ram or cylinder. To hold load, place lever into Neutral/Hold. Move lever to Retract position (as described above) to release load. -. Never operate the pump at 0,000 PSI without ram movement for more than minute without shifting the control valve to neutral. Leaving the valve in the advance or retract position without the piston rod moving will overheat the oil. --

6 SECTION IV MAINTENANCE WARNING: THE ELECTRICAL POWER CORD MUST BE DISCONNECTED FROM ELEC- TRICAL OUTLETS BEFORE PERFORMING MAINTENANCE OR REPAIR PROCEDURES. -. Maintain Oil Level -- check hydraulic oil level every 0 hours of operation. Add Simplex oil (Model # AO -- gallon) when necessary. Oil level should be no more than " from top of reservoir plate -- with cylinders retracted and motor off. Completely change oil at least twice a year. The following conditions require more frequent oil changes: a. Rigorous duty, where oil temperature may reach 0 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 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. -. Adjusting the External Relief Valve: a. Install gauge and gauge adapter between pump and cylinder. b. Remove cover to expose adjusting screw. Place valve lever in Neutral/Hold position and start motor. Move lever to direct pump output to pressure port (Advance). c. Insert allen wrench into adjusting screw in the hole on the lower left side of valve. d. Turn adjusting screw clockwise to increase, or counter clockwise to decrease pressure. (Do not exceed 0,000 PSI.) e. Check valve setting by shifting the valve to advance and retract cylinder several times. Maximum gauge reading should remain constant. -. Flushing the Pump. If you suspect your pump has been contaminated or discover sludge or other deposits on internal components, you should thoroughly flush the pump. a. Remove the old oil from the reservoir, then thoroughly 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 load condition for or 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. --

7 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 Sporadic Cylinder Action Cause -- Solution. Air in the hydraulic system. See Sec. - for correct bleeding procedure.. Check reservoir oil level. Motor Will Not Start Be sure power cord is not damaged. Check for tripped circuit breaker--be sure breaker is of adequate size. Have 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. Air in system. (See Sec. - for bleeding procedure).. Be sure the oil reservoir is filled to normal level.. Check all points where air might leak into system. Pump Oil is Over Heating. Oil viscosity too high. Replace with Simplex #.. Check for high pressure leakage on upper pressure plate. (Leaking at plug).. Oil level is low. Fill reservoir to normal level, or refit the pump with larger reservoir.. (See Section -) Pump Runs but Will Not Pump Oil. Pump is not primed. Run pump a few minutes tipping from side to side.. Check to make sure that externally adjustable relief valve set properly. Check internal relief valve.. Damaged O-Rings. Take to nearest Simplex service center for repair.. Defective control valve. (Troubleshoot separately). --

8 PUMP ASSEMBLIES

9 PUMP ASSEMBLIES PART NO. DISCRIPTION PART NO. DISCRIPTION Piston Pump Body Roller Bearing Thrust Bearing Race Bearing Ecc. Shaft Assm. Thrust Bearing Race Bearing Adaptor Shaft Assm. O-Ring Retaining Ring Adaptor Piston.0 Dia. Piston.0 Dia Piston Ball Stop / Socket Pipe Plug Piston Unloading Assm. Ball Retainer 0C-D Ball Bearing Intake Seat Tube Assm. R0-0B Ball Bearing Set Screw Nut-Hex Jam Soc Pipe Plug Steel Center Plate. Bottom Plate Gear Pump. Shaft-Idler Screen Guide Tube. SHCS /-x / Roll Pin Screw, Ball Stop Gasket SHCS /-x / Tube Return Shaft Adp. Backup Bearing Retaining Ring PIpe Plug Ext. Relief Seat Ext. Relief Cone Valve Relief Adjust Screw Ball /" Piston Block.0 SHCS /-x. Dump Piston Seal O-Ring Lever-Dump Pin Retaining Ring SOC Set Screw Nut-Self Locking Cone Seat Backup Washer O-Ring SHCS /-x/

10 PUMP ASSEMBLIES,, B 0 B A A B B B A 0 0

11 PUMP ASSEMBLIES,, PART NO. DISCRIPTION PART NO. DISCRIPTION 0 A B A B Piston Pump Body Roller Bearing Thrust Bearing Race Bearing Ecc. Shaft Assm. Thrust Bearing Race Bearing Adaptor Shaft Assm. O-Ring Retaining Ring Adaptor Piston. Dia. Adpt. Piston. () Adpt. Piston.0 () Piston. Dia. Piston. Dia. () Piston.0 Dia. () Piston Ball Stop / Socket Pipe Plug Piston Unloading Assm. Ball Retainer 0C-D Ball Bearing Intake Seat Tube Assm. R0-0B Ball Bearing Set Screw Nut-Hex Jam Soc Pipe Plug Steel Center Plate. Bottom Plate Gear Pump Shaft-Idler Screen Guide Tube Screw Plate-Screen Mount Screw Roll Pin / x / Ball Stop Screw Gasket 0 0 A B Ball mm Return Tube Backup Washer Bearing Retaining Ring PIpe Plug Ext. Relief Seat Ext. Relief Cone Valve Relief Adjust Screw Ball /" Piston Block. Piston Blk.. () Piston Blk..0 () SHCS /-x. SHCS /-x/ Dump Piston Seal O-Ring Lever-Dump Pin Retaining Ring SOC Set Screw Nut-Self Locking Cone Seat Backup Washer O-Ring

12 PUMP ASSEMBLIES B B 0 B B SECTION B-B

13 PUMP ASSEMBLIES PART NO. DISCRIPTION PART NO. DISCRIPTION Dump Pump Body Roller Bearing Thrust Bearing Race Bearing Ecc. Shaft Assm. Thrust Bearing Race Bearing Adaptor Shaft Assm. O-Ring Retaining Ring Adaptor Pump. Dia. Piston Pump. Dia Piston Ball Stop / Socket Pipe Plug Piston Unloading Assm. Ball Retainer 0C-D Ball Bearing Intake Seat Tube Assm. R0-0B Ball Bearing Set Screw Nut-Hex Jam Soc Pipe Plug Steel Center Plate. Bottom Plate Gear Pump Shaft-Idler Screen Guide Tube Screw Plate-Screen Mount Screw Roll Pin / x / Ball Stop Screw Gasket Return Tube Backup Washer Bearing Retaining Ring PIpe Plug Ext. Relief Seat Ext. Relief Cone Valve Relief Adjust Screw Ball / 0A- Dump Piston Seal O-Ring / x. Dump Leve Dump Pin Retaining Ring Screw Set Soc. Rd. Self Locking Nut Dump Cone Insert Seat Backup Washer -00 O-Ring

14 DUMP VALVE ASSEMBLY 0 A A PART NO. DESCRIPTION Dump Manifold Ball / Piston-Dump Valve O-Ring Backup Washer Compression / SOC Pipe Plug Ball Bearing / Compression Plug SAE # Port SOC Pipe Plug / Hex Pipe Plug Asm.

15 - B A BREAKER ASSEMBLY V MANUAL VALVE 0 A B 0V BROWN BLUE GREEN 0 PART NO. DESCRIPTION Mounting Bracket Plug & Cord Assm. Hose Clamp Rectifier A 0V Relay Sub-Asm 0 Series Transformer Sub Assm. Fitting, Cord Locknut / inch Bridge Rectifier Tie Cable RHMS 0- x / Nut 0- Screw Screw /-0 x / Hex Nut /-0 Wire # White Butt Connector Push On Terminal Spade Terminal wire # Black

16 - + N.O. A N.C. 0A 0V MEXICO -0 J N.O. A K K TEMPLETON, KENLY & CO, INC. K BOTTOM VIEW N.C. 0A 0V MEXICO MOUNTING BRKET ASSEMBLY TEMPLETON, KENLY & CO, INC. BOTTOM VIEW POTTER & BRUMFIELD TSA- N.O. A N.C. 0A 0V POTTER & BRUMFIELD TSA- N.O. A N.C. 0A 0V BOTTOM VIEW MEXICO BOTTOM VIEW MEXICO V JUMPER - & - 0V JUMPER - APPLY VOLTAGE TO & J ELEC CONNECT J TO ELEC & ELEC CONNECT J TO 0 K V JUMPER - & - 0V JUMPER - APPLY VOLTAGE TO & POTTER & BRUMFIELD TSA- POTTER & BRUMFIELD TSA- ELEC CONNECT J TO ELEC & ELEC CONNECT J TO BROWN 0 GREEN BLUE + PART NO. DESCRIPTION Mounting Bracket Circuit Board Assm. Bridge Rectifier RHMS 0- x / Cord Fitting Locknut / inch Plug & Cord Assm. Wire # White Push-On Terminal

17 0 MOTOR PENDANT ON OFF JOG GREEN BLK WHITE PART NO. DESCRIPTION 0 0 Pendant Body & Relief Junction Box Switch Pendant Cord 0

18 - BOX ASSEMBLY 0 & 0 SERIES PENDANT 0 A B BLK/GRN RED/BLK YLW/BLK BLK GREEN GRN/YLW GREEN BLUE GREEN BROWN ON OFF JOG BLK WHITE GREEN PENDANT SWITCH 0 0 PART NO DESCRIPTION Electrical Box w/ Cover Plug & Cord Assy. Motor Pendant Cord Fitting Locknut / Screw Nut 0 - Transformer 0 PART NO. 0 DESCRIPTION Butt Connector Wire # Black Relay VDC Coil Push-On Terminal Wire # White Wire Nut Rectifier A 0V Terminal Push On

19 BROWN BLUE GREEN A B ON OFF JOG + - JUMPER WIRE + - BLK GREEN WHITE E.M. PED SERIES DUMP PUMP 0, 0 & 0 SERIES PUMPS PENDANT SWITCH 0

20 PED00 PED00 PED00 PED00 Part Number PED00 PED00 PED00 PED00 PED00 PED00 PED00 PED00 PED00 Item# 0 0 Description RUBBER FOOT GAL SIMPLEX OIL PUMP ASSEMBLY RESERVOIR GASKET BREATHER VENT HEX STL. PIPE PLUG FILLER PLUG SCREW COVER WASHER SIMPLEX LOGO LABEL, SAFE USE BLANK DECAL DUMP VALVE ASSM. VALVE GASKET SHCS /-x / ADAPTER ASSM. PIPE PLUG COVER PLATE MOTOR HANDLE BRK. ASSM. HEAVY HEX JAM NUT BHSCS 0-x. LG SWITCH FITTING, CORD L-TIGHT LOCKNUT / SIMPLEX LOGO CIRCUIT BOARD PUSH ON TERMINAL RECTIFIER # JUMPER WIRE x0 MOTOR PENDENT TERMINAL PUSH ON SPER /-0x / SCREW STAINLESS WASHER HOLE PLUG / * * * * * * * * * * * * PED SERIES DUMP PUMP *High Voltage