The Simplex ES - Series

The Simplex ES - Series POW'R - RISER 00 TON Operating & Maintenance Instructions Capacity 00 Tons Height Closed/Ext. /" / 0 /" Weight lbs. FEATURES AND BENEFITS More rapid advance & Retract Quieter - Decibels Double acting Hydraulic cylinder Gage port included (Heavy Duty Design) with -way valve Serrated load cap & base & check valve Larger wheels (semi-pneumatic) Lighter - Aluminum housing Rocker plate More efficient - Operates despite Less maintenance required - easy to starved air conditions repair Available With Air, Gasoline or Electric Motor Revised - The world's most complete line of industrial, hydraulic and mechanical lifting and load-holding equipment. SIMPLEX DIVISION OF TEMPLETON, KENLY & CO., INC. Gardner Road Broadview, Illinois 0 (0) -00 / Fax (0) -0

CONTENTS Maintenance at a Glance Page Basic Assembly Instruction Fig. Page Basic Operating Instructions Fig. A & B Page & Part Sheet - Basic Assembly Fig. Page & Part Sheet - Basic Sub-Assembly Fig. Page & Part Sheet - Pump & Motor Assembly Fig. A & D Page 0 & Part Sheet - Stand. Cylinder Assembly Fig. Page Part Sheet - Control Valve Assembly Fig. & A Page & Part Sheet - Handle Support Fig. Page Part Sheet - Air Motor Fig. Page Part Sheet - Filter Lubricator Fig. 0 Page Part Sheet - " Min. Basic Assembly Fig. Page & 0 Part Sheet - " Min. Cylinder Assembly Fig. Page Maintenance: A. Oil Page B. Pump Assembly Page & C. Air Motor Page D. Disassembly Procedure Page Troubleshooting Page

POW'R-RISER MAINTENANCE & OPERATING TIPS. IMPORTANT: You must move the directional control valve handle to neutral (center position) 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 or retracted quickly heats and deteriorates the oil.. 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.. Normally change the hydraulic oil after every 0 hours of operation or every 0 days, whichever occurs first.. Hydraulic Oil: Keep clean Don't mix Use only Simplex #. Try to protect the piston rod from being struck with tools or other objects. Fully retract the rod when not in use.. Store in a clean, dry area. (Keep the hydraulic oil clean).. Adjust the lubrication assembly (#, Fig. 0) to or drops a minute, maximum. The lubricator is filled the an anti-freeze fluid (# - pint), and if needed, should only be replaced with that fluid. Suitable substitute is Killfrost.. Jack must be perpendicular to the load. Jacking on an angle can result in the jack slipping out and loss of the load (see Fig., Page ).

. ASSEMBLY INSTRUCTIONS The Pow'r-Riser was shipped with the handle assembly (#) and the Breather (#0 - fig. removed for ease of packaging. Remove the pipe plug located on the top reservoir casting by the motor mounting plate and thread in the breather (see fig. - #0 for location). # Handle Support Assembly # Roll Pin HANDLE ASSEMBLY Hole "B" Flush-roll pin assembled position. Slide handle assembly. (#) into handle support assembly. (#) until Hole "A" lines up with Hole "B".. Drive roll pin (#) into Hole "B" until it is flush with handle support assembly (#). Hole "A" # Handle Assembly The Pow'r-Riser is now ready for operation. Figure

TO RAISE LOAD: (Refer to Figures A and B). Pull out knob (item ) and swing handle assembly (Item ) up.. Place foot on pad (Item ) and pull out and down on handle assembly (Item ). Pow'r-Riser can 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 ) or by means of eye bolt (Item ). Never attempt to pick up jack by handle assembly (Item ) or swing handles.. At the work station, the jack should be positioned on a solid foundation (wooden blocks between 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.. Once the jack has been placed on support blocks, final positioning can be accomplished with swing down handles (Item A & B). Handle assembly (Item ) should be swung down out of the way prior to jacking.. Connect air supply to air valve (Item ). (/ - NPT). Open air valve (Item ) and move the directional control valve handle (Item ) to the advance position.. Never allow the jack to run without ram movement for more than minute without moving directional control valve to neutral. Letting the jack run with the valve in the advance or retract position after the piston rod has fully extended will overheat the jack.. 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 taken to keep the load level, as the Pow'r-Riser will run at a faster rate than any other similar jack on the market. Leveling should be accomplished by throttling the air valve.. Place solid stands under the load. 0. Place directional control valve handle (Item ) in the lower position (see figure A) lowering load onto stands. Place directional control valve handle in neutral position. Close air valve (Item ). TO LOWER LOAD:. Open air valve (Item ).. Move directional control valve handle to raise position (see Figure A).. When load clears stands, place directional control valve handle in neutral position. Remove stands.. Move valve handle (Item ) to the lower position.. When piston has fully retracted, place directional control valve handle in neutral (center) position and close the air valve.

Lower 0 S I M P L E X Figure A AIR MOTOR POWERED POW'R-RISER A Raise Figure B B

POW'R-RISER BASIC ASSEMBLY ITEM CONTROL # DESCRIPTION QTY. 0 00 0 0 0 0 0 0 Load Cap Filter/Lubricator Assembly Air Shut Off Valve Air Pump Assembly Hydraulic Oil/ Gallon Model Decal Pow'r-Riser Basic Assembly Hand Grip Valve Assembly Tube Assembly Elbow Drain Line Soc. Hd. Cap Screw Gasket Anti-Freeze Lub. Caution Decal Control Valve Plate ES Pow'r-Riser Decal USE FIG. SPECIFICATIONS:. Capacity: 00 U.S. Tons @, PSI. Stroke: Inches. Air Pr./Air Vol. Req'd.: 00 PSI/0 SCFM. Speed of Piston Travel Under Full Load: 00 PSI: / in./min. 0 PSI: / in./min. 0 PSI: in./min.. Reservoir Capacity: Gallons

POW'R-RISER BASIC ASSEMBLY 0 /" to " Oil Level FIGURE.. Min. 0. Max. S I M P L E X Rear Screen Must be relocated and assembled together along with the front. Screen at the assembly before test.

POW'R-RISER SUB-ASSEMBLY ITEM CONTROL # DESCRIPTION QTY. 0 0 0 0 0 0 0 0* 0* 00* 0* 0* 0* 0 0 0 0 000 00 00 0 * 0 0* 0 0* Cylinder Assembly Support Assembly Handle Assembly Housing Reservoir Handle Ring Set Screw Shaft Relief Valve Tire & Wheel Nipple Over Center Valve Hose Assembly Hose Assembly Pipe Nipple Pipe Nipple Elbow Street Elbow Socket Pipe Plug O-Ring Roll Pin Roll Pin Soc. Hd. Cap Screw Hex Cap Hex. Slotted Nut Hex. Jam Nut Plate Washer Lock Washer Cotter Pin Breather Vent & Filter Nylon Washer Base Hex. Head Screw Washer Safety Valve Enclosure Kit Eye Bolt Swivel Fitting Caution Decal Spacer Elbow Nipple Elbow 0 USE FIG. * Included in O.C. Valve Kit #00 that will completely interchange with older valves.

POW'R-RISER SUB-ASSEMBLY 0 0 0 Fill Plug Torque to Max. 0 ft.lb. View A-A USE FIG.. (Ref.) +.0-00. (Typ.) +00 -.0.0 Gap (Typ) wheels must have free rotation 0. 0 0 0 0 Drain Torque to 0 in. lbs..

PUMP & MOTOR MOUNTING ASSEMBLY #00 ITEM CONTROL # DESCRIPTION QTY. 0 0 0 0 0 0 00* 0 00 0 0 0 0 0 000 0 * 00 * 0 0 0 0 0 0 0 0 Motor Air Gasket Cover Plate Gasket-High Pressure H.P. Plate Assembly S.H.C.S. Adapter Valve Back Up Washer O-Ring Tube High Flow Bearing Thrust Race Bearing Eccentric Assembly Race Bearing Bearing Thrust Race Bearing O-Ring Back-Up Washer Piston Block Assembly O-Ring Low Pressure Plate S.H.C.S. Gear Pump H.H.C.S. Lock Washer Suction Strainer Key Tube Assembly Seal Plate Assembly B.H.C. Screw Nipple St. Elbow Reducer Bushing USE FIG.A * For details, see figures B, C, & D. 0

PUMP & MOTOR MOUNTING ASSEMBLY C C Bend tube assembly to insurer proper positioning Position hi-flow cartridge as required to assemble lubricator. Lubricator assembly shown in final location View A-A Scale / View C-C 0 Ref. USE FIG. A 0 Torque to 0 in. lbs. 0 0 Torque to 00 in. lbs. Torque to 00 in. lbs. A A

HIGH PRESSURE PLATE ASSEMBLY #00 Figure B 0 Item 0 Control Descr. Qty. 00 0 0 0 000 000 0 0 0 0 0 0 00 0 0 0 Scr. Adj. Cartridge Guide Ball Sprg. Hi-Flow Ball B-U Washer O'Ring Relief Vlv. S.H.C.S. Gasket Wshr. Ck. Valve Spring Ball S.H.C.S. Gasket Wshr. Pilot Spl. Brg. w/seal H.P. Plate 0 PISTON BLOCK ASSEMBLY # Item Control Descr. Qty. Figure C 0 0 00 0 0 00 0 0 0 0 Block Piston Ball Spring Washer/Copper Screw Spring Ball Retain. Intake-Seat Sprg Piston Piston LOW PRESSURE PLATE ASSEMBLY # Item Control Descr. Qty. Figure D. 0 0 Low Pres. Plate Pipe Plug Bushing

CYLINDER ASSEMBLY #0 0 Tighten Screws to 0 Ft. Lbs. Torque. Dia. Ref. Figure. Ref.. Ref. -Ports (In Line) Ref. Relief Valve Port Item Control Descr. Qty. 0 0 00 0 0* 0* 0* * 00* Cyl. Bdy. Weld Piston Rod Head Gland O'Ring B-U Ring Rod Seal Piston Seal Rod Wiper Steel Plate Screw * Items are included in the Packing Kit #.

CONTROL VALVE ASSEMBLY # Item Control Description Qty. 0 0 0 0 0 Control Valve Manifold (Barksdale Val.) S.H.C. Screw / - x Lg. Pipe Plug - Flush Type Gasket / x / Hex Nipple / Female Pipe Swivel Adpt. / x Hex Nipple / Female Pipe Swivel Adpt. Figure Torque to 00 In. Lbs. / - NPTF Gage Port (Retract) / - NPTF Gage Port (Extend)

VALVE # 0 0 A "A" "A" View "A-A" Figure A INTERCHANGEABLE WITH # ITEM CONTROL # DESCRIPTION QTY. 0 0 0 00 0 0 0 00 0 0 0 00 0 0 0 0 0 000 Rotor Assembly O'Ring Subplate-Valve. O'Ring Thrust Washer Thrust Bearing O'Ring Upper Valve Blk. Detent & Stop Plt. Driv-Lok Pin O'Ring Back-up Washer Shear Seal Spring Washer Detent Spring Ball.0 Dia. Washer-Handle Flat Grip Handle Acorn Nut /-0 Soc. Hd. Capscrew O'Ring

HANDLE SUPPORT ASSEMBLY # Item Control Description Qty. 0 Support Pin Nut Spring Retaining Nut Figure

PARTS LIST - AIR MOTOR #0 0 0 0 Figure 0 Item Control Description Qty. 0 0 00 00 00 00 00* 00* 00* 00* 00* 000* 00 00* 00 00* 00 00 00 00 00* 00 00 Body End Plate, Drive End Plate Rotor Assembly Vane Vane Spring Push Pin Bearing, Drive End Shaft Seal Body Spacer Gasket End Cap, Drive End O'Ring End Cap, Dead End Cap Gasket Muffler Assembly Felt Screen Drive Key Bearing, Dead End Dowel Pin Repair Kit, Motor *Items Included in Repair Kit #00

FILTER - LUBRICATOR ASSEMBLY # Air Pressure Inlet /" Steel Pipe Nipple #0 Air Fliter # Fill Plug Oil Drop Regulator Elbow # Bracket # Lubricator # To Motor Inlet Port Coupling #0 /" Union - # /" Steel Pipe Nipple #0 /" Steel Pipe Nipple #0 Figure 0 Nipple #0 Elbow # Nipple # Elbow #0

00 TON POW'R-RISER " MINIMUM

POW'R-RISER SUB-ASSEMBLY INCH MINIMUM ITEM CONTROL # DESCRIPTION QTY. 0 0 0 0 0 0 0 0 0 00 0 0 0 0 0 0 0 000 0 00 0 0 0 0 0 Cylinder Assembly Support Assembly Handle Assembly Housing Reservoir (Machined) Handle (Machinedº Ring /"-0 x / Set Screw Shaft Relief Valve (0,000 lbs.) x Semi-Pneu. Tire & Wheel " Lg. Nipple Over Center Valve /" x " Hose Assembly/Spg. /" x " Hose Assembly/Spg. /" x /" Pipe Nipple /" x " Lg. Pipe Nipple /" x 0 Elbow /" x 0 Street Elbow /" Socket Pipe Plug -/" x " x /" O-Ring /" x " Lg. Roll Pin /" x." Lg. Roll Pin /"- x " Lg. Soc. Hd. Cap Screw /"- x -/" Lg. Ft. Hd. Hex Cap /"-0 Hex. Slotted Nut -/"- Hex. Jam Nut /" Plate Washer /" Lock Washer /" x -/" Cotter Pin Breather Vent & Filter Base /"- x -/" Lg. Hex. Hd. Screw /" Washer Safety Valve Enclosure Kit /" Threaded Eye Bolt /" Swivel Fitting Caution Decal Spacer (/ Thick) /" x 0 Elbow /" x -/" Lg. Nipple /" x 0 St. Elbow USE FIG.

POW'R-RISER SUB-ASSEMBLY INCH MINIMUM USE FIG.. 0 0 0. Torque to.0 In. lbs. 0 DRAW 0 NOTE: For part numbers no shown in Fig. - (" Min.), refer to standard Pow'r-Riser Fig. -D and -0. 0

CYLINDER ASSEMBLY INCH MINIMUM #0 0 DIA. REF. Tighten Screws to 0 Ft. lbs. Torque.. REF. REF. NOTE: Items with * are included in the packing kit # Figure -Ports (In Line) REF. Relief Valve Port Item Control Descr. Qty. 0 0 00 0 0* 0* 0* * 00* 0 Cyl. Bdy. Weld Piston Rod Head Gland O'Ring B-U Ring Rod Seal Piston Seal Rod Wiper Steel Plate Screw

MAINTENANCE INSTRUCTIONS A. OIL. The "full level" of the reservoir is approximately gallons. Fill within " from the top of reservoir as needed. Check regularly.. The use of Simplex oil is highly recommended. Simplex oil contains a complete additive package including anti-wear, oxidation inhibitors and anti-foam additives. NOTE: USING OIL WITH IMPROPER VISCOSITY WILL DAMAGE PUMP COMPONENTS. 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 your fingers. Gritty oil must be changed. Normally change the hydraulic oil after every 0 hours of operation or every 0 days, whichever occurs first.. Water in the reservoir can deteriorate oil and damage pump components. One source of water contamination is from the condensation of ambient air in the reser voir. To minimize this condition, keep the jack fully retracted and the reservoir full when not in use. Water can be drained from jacks that have sat idle for hours, as water accumulates in the bottom of the reservoir. Tilt the jack back and when the drain plug (#, fig. ) 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, if you 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 condensation 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). Clean Oil Filter Screen Periodically. a. Loosen and remove reservoir plate bolts and retract tube assembly (#0, fig. ). 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.

MAINTENANCE INSTRUCTIONS (CON'T) B. PUMP ASSEMBLY (Con't). 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. 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 to the reservoir assembly. C. AIR MOTOR AND FILTER LUBRICATOR The air motor is a precision built rotary type motor. The top clearance (between rotor and bore) is.00". The total end clearance (between the sides of the rotor and the end plates) is.00". The vanes take up their own wear and will last,000-,000 hours, depending upon speed, method of oiling, operating pressure, and precautions taken in maintaining the motor. The type of shaft seal used does not lend itself to operating pressures above 00 PSI (. Bar-Metric). Allowing excess moisture or foreign particles 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 and control of speed, use air lines of not less than / inch pipe size. When coupling or connecting the motor to a driven member, avoid any end or side thrust on the output shaft and especially DO NOT HAMMER ON SHAFT. The starting torque is less than the running torque and could vary depending on the position at which the vanes stop in relation to the air intake port. The speed and torque can be regulated by using a pressure regulator or a simple shut-off valve. Lubrication is necessary for the shaft seals, and rust prevention. It can be accomplished by the installation of an automatic air line oiler set to feed - drops per minute. Use Simplex # anti-freeze oil. Excessive moisture in the air line can cause rust formation in the motor and might also cause ice to form in the muffler due to expansion of air through the 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 the shaft by hand in both directions for a few minutes, again connect the air line and apply pressure slowly until there is no trace of solvent in exhaust air. (Keep face away from exhaust 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 in the chamber. If the vanes need replacing, or foreign particles are present in motor chamber, an experienced mechanic may remove the end plate opposite the drive shaft end. DANGER TO PREVENT EXPLOSIVE HAZARD, DO NOT PUMP COMBUSTIBLE LIQUIDS OR VAPORS THROUGH THESE UNITS.

MAINTENANCE INSTRUCTIONS PARTS ARE DESIGNATED WITHIN PARENTHESES BY FIGURE NO. & ITEM NO., i.e., (-) indicates (Figure - item ) 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 (-) through all three positions a few times with the air disconnected. Failure to release pressure may result in injury. a. Drain reservoir by removing plug, #0 (-). b. Disconnect tube assembly, #0 (-0). c. Remove () mtg. screws, # (-). d. Lift the left side of pump mtg. assembly, disconnect hose assemblies # (-) and # (-), from the bottom of pump mounting assembly. e. Carefully remove pump mtg. assembly. Cylinder Piston Removal (Seal Replacement) (Refer to Figures & ) a. Remove load cap, # (-0). b. Raise the piston almost all the way up. c. Remove head gland nut, #0 (-). Take piston rod, #00 (-) out from the cylinder. Cylinder Body Removal (Refer to Figures & ) a. Follow pump removal steps (a-e) above. b. Remove hoses, # (-) and # (-). c. Remove overcenter valve assembly (Fig., View A-A) d. Remove pipe nipple, # (-) along with elbow #0 (-) e. Remove pipe nipple, # (-) and relief valve, #0 (-) f. Remove () aluminum base mtg. screws, #00 (-) and (0) washers #00 (-). g. Take off nylon washer, # (-); remove () mtg. screws, # (-). h. Remove ring, # (-). i. Remove steel plate mtg. screws, # (-0). j. Pull off reservoir, # (-), from cylinder. k. Remove gland nut, #00 (-). l. Take out piston rod, #0 (-). m. Replace seals as required. n. Reassemble in reverse order. (See following notes.) Care must be taken to reassemble () washer #0 (-) in the same pattern as shown in Figure.

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 Noisy Operation Pump Oil is Overheating Pump runs by will not pump oil, or piston rod moves by will not lift load. Piston extends by will not retract. Cause -- Solution. Air in the hydraulic system. Cycle the jack several times under no load.. Check reservoir oil level.. Air in system. (Same as Above). Be sure the oil reservoir is filled to normal level.. Check all points where air might leak into system.. 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.. See # of page.. Pump is not primed. Run pump a few minutes, tipping jack back and forth.. Check internal relief valve.. Flush filter screen.. Defective control valve. (Troubleshoot separately or replace valve).. Replace o-ring ( &, Fig. B). Damaged o-rings. Take to nearest Simplex service center for repair.. Pump not developing enough pressure. (,00 PSI required for retraction) a. Check for internal pressure leaks. b. Adjust internal relief. (#, Fig. B) c. Replace o-rings. (# &, Fig. B). Defective O.C. Valve (#, Fig. ) Replace.