2525 GARDNER ROAD, BROADVIEW, IL www x.c

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1 GARDNER ROAD, BROADVIEW, IL www x.c G SERIES ELECTRIC STANDARD POWER PUMP PARTS IDENTIFICATION MANUAL Reference # - TD0 Rev. - A Date - /0 This illustration is for reference purposes only. The appearance of your unit may differ from the unit shown. Valve Sub-Assemblies pg. - Pendant - pg. - Manifold Sub-Assembly - pg. Common Components used in all G Series pumps - pg. - Pump Sub-Assemblies and Sub-Components pg. -

2 G Series Electric How to Identify Parts for Your Model. MODEL MATRIX Understanding our model number configurations: PUMP CLASS Sample Model #: G Model Performance Series Power Consumption Valve Function Reservoir Size Description: 0 = Dump 0 = Gal Plastic G = Gen II Pump = VAC = / HP = Way Dump = Gal Metal = Way Manual = 0 VAC = Way Manual = Way Manual = Way Solenoid = Port Block PUMP TYPE MODEL NUMBER & DATE CODE LOCATION DATE CODE COVER PLATE STAMPING LOCATION MODEL DECAL PLACEMENT

3 SKIN PUNCTURE/ HYDRAULIC LINE BEFORE OPERATING PUMP:. Be sure the electrical connection is grounded. SKIN PUNCTURE/ HYDRAULIC LINE U.S. PAT. NO.,,0 BEFORE OPERATING PUMP:. Be sure the electrical connection is grounded. REVIEW ALL OPERATING INSTRUCTIONS. Check that your power supply agrees with the motor nameplate.. Use only equipment rated for 0,000 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.. 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 REVIEW ALL OPERATING INSTRUCTIONS 0,000 PSI/ 00 BAR. Never operate the pump without tool movement for more than minute without shifting the control 0 0,000 PSI/ 00 BAR K K J J 0 K K J J 0 G Series Electric Common components used in pumps NOTE: This illustration is for reference only. The appearance of your unit may differ from the unit shown. RELIEF VALVE MANUAL VERSION SIMPLEX UNLOADING VALVE RETRACT SUC-O-MATIC HOLD ADVANCE ELECTRIC PUMP INSTRUCTIONS FOR SAFE OPERATION 0 IN*LBS 0 TASD- TASD- N.O. 0A N.O. 0A N.C. 0A N.C. 0A 0VAC 0VAC TEMPLETON, KENLY & CO. INC. + VDC PCB REV- ELEC CONNECT J TO ELEC & ELEC CONNECT J TO - VDC SIMPLEX V JUMPER - & - 0V JUMPER - APPLY VOLTAGE TO & Series G / hp, Kw 0 DUMP VERSION RELIEF VALVE PCB REV- 0 TASD- TASD- N.O. 0A N.O. 0A N.C. 0A N.C. 0A 0VAC 0VAC TEMPLETON, KENLY & CO. INC. + VDC ELEC CONNECT J TO ELEC & ELEC CONNECT J TO - VDC SIMPLEX V JUMPER - & - 0V JUMPER - APPLY VOLTAGE TO & ELECTRIC PUMP INSTRUCTIONS FOR SAFE OPERATION 0 IN*LBS. Check that your power supply agrees with the motor nameplate.. Use only equipment rated for 0,000 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. 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. Series / hp, Kw G 0

4 G Series Electric Common components used in pumps ITEM # DSCRIPTION V. 0 V. QTY. 00 PUMP ASSEMBLY G SEE PAGE RESERVOIR GALLON (STEEL) 0P 0P RESERVOIR GALLON (PLASTIC RES) RESERVOIR GASKET (STEEL) RESERVOIR GASKET (PLASTIC RES) BREATHER VENT PIPE PLUG /" FLUSH W/ COATING HEX PIPE PLUG /" W/ COATING HHCS /-0 X. PLT SCREW /-0 X / ST (PLASTIC RES) SEALING WASHER SCREW /-0 X ST (PLASTIC RES) RESERVOIR DECAL G.00 0 LABEL SAFE USE ELEC BLANK DECAL X MANIFOLD ASSM SEE PAGE.00 0 VALVE GASKET.00 0 VALVE GASKET (DUMP VALVE).00 0 SHCS /- X /.00 0 SHCS /- X / DUMP.00 0 ADAPTER ASSY HEX PIPE PLUG /".00 0 HEX PIPE PLUG /" ( WAY/WAY /DUMP).00 O SHCS /- X / DUMP.00 0 VALVE ASM SEE PAGE LABEL, POSITION WAY LABEL, POSITION WAY.00 0 MAGNET O SHROUD ASSEMBLY V/ 0V SEE PAGE DECAL OVERLAY.00 0 SIMPLEX LOGO.00 O PIPE PLUG /" FLUSH W/ COATING SHCS /-0 X / LG.00 0 SIMPLEX LOGO.00 0 SIGHT GAUGE MOTOR GASKET POW'R BUDDY.00 0 GASKET POW'R BUDDY PUMP COVER PLATE POW'R BUD.00 0 SHCS #0- X 0.0 LG HEX JAM NUT # FHCS 0- X 0.0LG.00 0 LOCKWASHER EXTERNAL TOOTH #0 Y000 Y000.00

5 G Series Electric Pump Assembly (SS) PUMP ASM. ITEM # DESCRIPTION PART # QTY. 00 POW'R BUD PUMP ASM SEE PAGE POW'R BUD VLV BODY ASM. SEE PAGE SHCS /- X " LG POW'R BUD TUBE.00 (SS) PUMP ASM. (DUMP PUMPS) 0 IN*LBS ITEM # DESCRIPTION PART # QTY. POW""R BUD PUMP ASM SEE PAGE - POW""R BUD DUMP ASM SEE PAGE - SHCS /- X "" LG POW""R BUD TUBE

6 G Series Electric Pump Sub Assembly (SS) PUMP SUB ASM. 0 0 SET SCREW SHOULD BE ASSEMBLED. TO TURNS BELOW SURFACE F IN*LBS. 0 TORQUE ALL /- BOLTS TO IN*LBS. 0

7 G Series Electric Pump Sub Assembly (SS) PUMP SUB ASM. ITEM # DESCRIPTION PART # QTY. 00 POW'R BUD C PUMP MAC POW'R BUDDY PISTON BLOCK ASSEMBLY SEE PAGE SHCS /- X MALE ELBOW / PIPE O-RING /X/ SET SCREW /- X / HOLLOW POW'R BUDDY RESTRICTOR SPRING BALL /" SHCS /- X.LG REDUCING GEAR POW'R BUDDY PUMP SHAFT.00 0 ROLL BRG /ID X /.00 0 POW'R BUD ECC RING.00 0 ROLL BRG / X /.00 0 BEARING ROLLER /x/x/ WIDE.00 0 O RING /X/ GEAR-SET G PUMP DS.00 0 BALL /" ROLL BEAR /IDX/ POW'R BUD BOTTOM PLATE.00 0 POW'R BUDDY WEAR PLATE.00 0 POW'R BUDDY ECCENCTRIC RING.00 0 THRUST WASHER /"ID.00 0 THRUST BRG /" ID.00 0 POW'R BUDDY IDLER SHAFT.00 0 RING-RETAINING.00 0 WASHER /" SS.00 0 POW'R BUDDY SCREEN.00 0 O-RING /X/ TUBE-GUIDE SHCS /- X /.00 0 SET SCREW #0- X / CUP.00 0 BALL /" O-RING /X/ 00.00

8 G Series Electric Pump Sub Assembly (SS) PUMP SUB ASM. (DUMP PUMPS) B B A A A IN*LBS. IN*LBS. 0 SECTION B-B ASSEMBLE ITEM PIN WITH KNURL ON THIS SIDE 0 IN*LBS. IN*LBS.

9 G Series Electric Pump Sub Assembly (SS) PUMP SUB ASM. (DUMP PUMPS) ITEM # DESCRIPTION PART # QTY PB VALVE BODY SECT. BALL /" 0 SPRING GASKET /X/ SCREW, BALL STOP MALE ELBOW / PIPE UNLOADING PISTON ASM PAGE 0 BALL /" POW""R BUDDY SPRING CAP 0 SPRING UNLOADING VLV O-RING /X/ 00 POW'R BUDDY ADJUSTING SCRE O-RING /X/ 00 SEAL DUMP PISTON LEVER-DUMP POW""R BUD DUMP PIN SET SCREW #0- X.0 OVAL NUT- 0- SELF LOCKING 00 0 SPRING CONE, DUMP O-RING /X/ 000 BACKUP WASHER 000 SEAT, INSERT / SOC PIPE PLUG 0 / FLUSH PLUG W/ SEALANT / SOC PIPE PLUG SEAT - EXT RELIEF 00 CONE - EXT RELIEF 00 SPRING - RELIEF VALVE 0 0 ROLL PIN / x / PLUG SAE #

10 G Series Electric Sub Component Assemblies (SS) UNLOADING PISTON ASM. ITEM # DESCRIPTION PART # QTY. 000 LOCTITE #RC/ UNLOAD PISTON O RING /X/ BACKUP WASHER DOWEL PIN / DIA X /.00 (SS) PISTON BLOCK ASM.. IN*LBS. 00 IN*LBS IN*LBS. ITEM # DESCRIPTION PART # QTY. 00 POW'R BUDDY PISTON BLOCK BALL /" SPRING BALL STOP BALL RETAINER INTAKE SEAT GASKET / X / PLUG PISTON BLOCK GASKET /X/ ADAPTER-.0 PISTON SPRING, PISTON PISTON-.0 DIA.00 0 PIPE PLUG /" FLUSH W/ COATING

11 G Series Electric Pump Sub Assembly (0SS) VALVE BODY ASM.

12 G Series Electric Pump Sub Assembly (0SS) VALVE BODY ASM. ITEM # DESCRIPTION PART # QTY. 00 PB VALVE BODY SECT BALL /" POW'R BUDDY JUNCTION SPRING GASKET /X/ SCREW, BALL STOP MALE ELBOW / PIPE UNLOADING PISTON ASM SEE PAGE BALL /" POW'R BUDDY SPRING CAP SPRING UNLOADING VLV.00 0 O-RING /X/ POW'R BUDDY ADJUSTING SCREW.00 0 / SOC PIPE PLUG.00 0 O-RING /X/ BACKUP WASHER POW'R BUD DUMP PLUG.00 0 / SOC PIPE PLUG SEAT - EXT RELIEF CONE - EXT RELIEF SPRING - RELIEF VALVE ROLL PIN / X /.00 0 PLUG SAE #.00

13 G Series Electric Valve Assembly PART#0SS (DUMP ASM). 0 SECTION A-A. 0 IN*LBS. A A ITEM # DESCRIPTION PART # QTY. DUMP VALVE FINISHED P DUMP VALVE PISTON BACKUP WASH TEF -00 O RING /X/ 000 COMPRESSION SPRING PLUG SAE # PORT DUMP VALVE SPACER DUMP VALVE CONE WY 0 SAE # SOC. PLUG 0 DUMP VALVE SPRING F ELBOW / 0 DEGR STRT 0 PIPE PLUG 0 PART#SS ( WAY DUMP ASM) NOTE: IN*LBS. 0 SECTION A-A POSITION HANDLE SO THAT VALVE IS CLOSED IN POSITION SHOWN. 0 IN*LBS. 0 IN*LBS. A A ITEM # DESCRIPTION PART # QTY. DUMP VALVE FINISHED P DUMP VALVE PISTON BACKUP WASH TEF -00 O RING /X/ 000 COMPRESSION SPRING ADAPTER 0 VALVE STEM WAY BALL /DIA. 00 DUMP VALVE PLUG 0 0 SPRING WAY VALVE 0 F ELBOW / 0 DEGR STRT 0 O-RING SAE PORT # 00 FHMS 0-X.0LG LEVER P0 PIPE PLUG 0 O-RING SAE PORT # 00 SPACER WAY VALVE 0

14 G Series Electric Valve Sub Assembly (0SS) WAY MANUAL (0SS) WAY MANUAL (SS) WAY MANUAL PART# ITEM # DESCRIPTION WAY VAL. QTY. 0 WAY VALVE BALL VALVE STEM O-RING BACKUP WASHER SCREW.00 0 VALVE HANDLE ROLL PIN.00 0 SEAT - EXT RELIEF CONE - EXT RELIEF SPRING - RELIEF VALVE ACORN NUT 0.00 WASHER.00 ADJUSTING SCREW 0.00 ADAPTER ASSY..00 SPRING.00 NS PIPE PLUG 0.00 / SOC PIPE PLUG 0.00 HEX ST. PIPE PLUG.00 0 SPRING CAP.00 LOCKWASHER Y NS = NOT SHOWN RELIEF REPLACEMENT KIT ( ++ = COMPONENTS) -- PART # ITEM # DESCRIPTION WAY VAL QTY. WAY VAL QTY. 0 VALVE ROTOR O-RING *.00 *.00 0 SUBPLATE- VALVE O-RING *.00 *.00 0 THRUST WASHER THRUST BEARING O-RING *.00 *.00 0 UPPER VALVE BLOCK DRIVE LOK PIN O-RING *.00 *.00 WASHER *.00 *.00 SHEAR SEAL SPRING WASHER DETENT SPRING BALL VALVE HANDLE SCREW SCREW NS SCREW O-RING *.00 *.00 SHEAR SEAL LOCKWASHER Y Y PACKING KIT & WAY MANUAL VALVE ( * = COMPONENTS) -- PART # 0

15 G Series Electric Manifold Sub Assemblies (0SS) WAY STANDARD PART# PART# ITEM# DESCRIPTION WAY MAN. ASM QTY. ITEM# DESCRIPTION WAY MAN. ASM QTY. 0 RET. VALVE MANIFOLD.00 NS PIPE PLUG NOZZLE-VALVE.00 0 PIPE PLUG-FLUSH SEAT - EXT RELIEF *.00 0 O-RING CONE - EXT RELIEF *.00 0 WASHER.00 0 SPRING - RELIEF VALVE *.00 ACORN NUT 0.00 ADJUSTING SCREW 0.00 NS = NOT SHOWN RELIEF REPLACEMENT KIT (* = COMPONENTS) -- PART # 0 (00SS) WAY STANDARD PART# PART# ITEM# DESCRIPTION WAY MAN. ASM QTY. ITEM# DESCRIPTION WAY MAN. ASM QTY. 0 VALVE MANIFOLD SPRING - RELIEF VALVE *.00 0 ADJUSTING SCREW CONE - EXT RELIEF *.00 0 ACORN NUT SEAT - EXT RELIEF *.00 WASHER.00 0 PIPE PLUG 0.00 RELIEF REPLACEMENT KIT (* = COMPONENTS) -- PART # 0

16 + VDC TASD- N.O. 0A N.C. 0A 0VAC - VDC TASD- N.O. 0A N.C. 0A 0VAC TEMPLETON, KENLY & CO. INC. G Series Electric Shroud Assembly DS00 (V. ASSEMLBY) K K E.M. V JUMPER - & - 0V JUMPER - APPLY VOLTAGE TO & J J ELEC CONNECT J TO ELEC & ELEC CONNECT J TO PCB REV- 0 GREEN BROWN BLUE PENDANT BROWN BLUE GRN/YLW 0 0 IN*LBS V JUMPER - & - 0V JUMPER - APPLY VOLTAGE TO & PCB REV- 0 K K J + VDC TASD- TASD- N.O. 0A N.O. 0A N.C. 0A N.C. 0A 0VAC 0VAC J TEMPLETON, KENLY & CO. INC. ELEC CONNECT J TO ELEC & ELEC CONNECT J TO - VDC ITEM # DESCRIPTION PART # QTY POW""R BUD MOTOR V POWR BUDDY SHROUD POW""R BUD BRACKET CIRCUIT BOARD ASM VDC PUSH NUT BOLT RET#0 ACORN NUT 0- PLTD PLUG AND CORD - IEC DUMP PENDANT STRAIN RELIEF 0 0 SPADE, TERMINAL SCREW, FILL HD MACH 0

17 V JUMPER - & - 0V JUMPER - APPLY VOLTAGE TO & + VDC TASD- N.O. 0A ELEC & ELEC CONNECT J TO - VDC N.O. 0A TEMPLETON, KENLY & CO. INC. G Series Electric Shroud Assembly DS00 (0V. ASSEMLBY) E.M. J K N.C. 0A 0VAC ELEC CONNECT J TO J K TASD- N.C. 0A 0VAC PCB REV- MOVE JUMPER TO & 0 GREEN BROWN BLUE PENDANT BROWN BLUE GRN/YLW 0 0 IN*LBS V JUMPER - & - 0V JUMPER - APPLY VOLTAGE TO & PCB REV- 0 K K J + VDC TASD- TASD- N.O. 0A N.O. 0A N.C. 0A N.C. 0A 0VAC 0VAC J TEMPLETON, KENLY & CO. INC. ELEC CONNECT J TO ELEC & ELEC CONNECT J TO - VDC ITEM # DESCRIPTION PART # QTY POW""R BUD MOTOR 0V POWR BUDDY SHROUD POW""R BUD BRACKET CIRCUIT BOARD ASM VDC PUSH NUT BOLT RET#0 ACORN NUT 0- PLTD CORD AWG 00V R DUMP PENDANT STRAIN RELIEF 0 0 SPADE, TERMINAL SCREW, FILL HD MACH 0 PLUG 0 AMPS-0V 0