Oakmont Lane, Westmont, IL 609 1.800..9114 Outside U.S. 1-60-90-6990 www.tksimplex.com G SERIES IR TORQUE PUMP PRTS IDENTIFICTION MNUL Reference # - TD09 Rev. - Date - 8/10 This illustration is for reference purposes only. The appearance of your unit may differ from the unit shown. Pendant ssembly - pg. 1 Valve Sub-ssemblies - pg. 8-9 Manifold Sub-ssembly - pg. 10 Pump Sub-ssemblies and Sub-Components - pg. - Series G 1 hp 1/ 1,1 Kw 460 Common Components used in all G Series pumps - pg. -4 Reservoirs - pg. 1
How to Identify Parts for Your Model. MODEL MTRIX Understanding our model number configurations: PUMP CLSS Sample Model #: G Model Performance Series Power Consumption Valve Function Reservoir Size Description: G = Gen II Pump = HP ir Motor = Rotoary Vane PUMP TYPE = Torque Wrench 4Way/ Position = 1. Gallon =. Gallon T OPTION 1 Options T = Torque Wrench MODEL NUMER & DTE CODE LOCTION DTE CODE COVER PLTE STMPING LOCTION MODEL DECL PLCEMENT Series G 11/ hp 1,1 Kw 460
SKIN PUNCTURE/ HYDRULIC LINE REVIEW LL OPERTING INSTRUCTIONS EFORE OPERTING PUMP: 1. Check instruction manual for required air supply.. Use dry lubricated air. 100 PSIG maximum. ntifreeze lubricant should be used in oiler and muffler to prevent freeze-up.. Use only equipment rated for 10,000 PSI / 00 R. 4. Make sure all connections are tight, secure and kink-free.. Check the reservoir oil level. Fill to one inch of the top, if necessary. 10,000 PSI/ 00 R 6. Never operate the pump without tool movement for more than 1 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 140 F or 60 C. FTER COMPLETING THE JO: 1. efore 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 MINTENNCE: 1. 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. 6894 G Torque Wrench Common Components 1 9 6 9 9 8 IN*LS P @ PENDNT P LCK LCK 8 1 P YELLOW YELLOW P 8 9 0 IN*LS HOSE CONNECTION DIGRM P 89 9 DVNCE COIL DVNCE COIL 90 81 MOTOR 96 6 64 P 41 0 IN*LS 84 8 19 0 9 1 88 1 91 OTH ENDS OF HOSE 0 IN*LS STOP RUN 1 16 1 1 Series G 11/ hp 1,1 Kw 460 4 6 0 IN*LS 1 0 1 0 IN*LS USE REMOVLE THRED LOCK TO SEL THREDS 9 8 9 4 10 4 IR PUMP INSTRUCTIONS FOR SFE OPERTION 11 0 IN*LS 6 0 IN*LS
Common Components ITEM # DESCRIPTION PRT # QTY. PUMP SM. G STGE SEE PGE - 1 RESERVOIR SEE PGE 1 1 4 RESERVOIR GSKET 8469 1 RETHER VENT /8" NPT 4648 1 6 PIPE PLUG 1/" W/ COTING 4669 1 SE #1 HEX PLUG WITH PORT 46118 1 8 HHCS 1/4-0 X. PLT 6891 14 9 SELING WSHER 689 14 10 RESERVOIR DECL G 460 11 SFE USE DECL IR 6894 1 1 LNK DECL X 4 80 1 1 MNIFOLD SM. TORQUE WRENCH SEE PGE 10 1 14 VLVE GSKET 694 1 1 SHCS /8-16 X /4 9991 16 VL DP SEE PGE 9 1 1 HEX PIPE PLUG /8" W/ COTING 461 1 19 IR SOLENOID 4W/P NORMLLY RETRCT SEE PGE 8 1 0 SHCS /8-16 X 1/ 886 4 1 LOCKWSHER /8 PLTED 994 6 ROLL PIN 1/8 X /8 LG 61604 1 4 MGNET 6601 1 HNDLE 468 1 DECL OVERLY 469 1 41 PENDNT IR TORQ WRE SEE PGE 1 1 SIGHT GUGE 46009 1 1/4 IN NIPPLE 410006 1 8 1/4" NIPPLE CT10 1 9 1/4" SELF-LOCKING COUPLER 46 1 6 GUGE SHROUD SSEMLY TORQUE WRENCH SEE PGE 1 64 HCS 10-4X.0 16SS 449 4 6 GUGE SHROUD MOUNTING PLTE 4688 0 GSKET-MOTOR 6601 1 1 PUMP GSKET G 460 1 STREET ELOW 8644 1 COVER PLTE G TORQUE WRENCH 464 1 4 PIN,DOWEL /16 1" LONG 6906 1 SHCS /8-16 X /4 LG 9084 4 6 IR MOTOR 6M PINTED LCK 8644 1 8 FHCS 1/4-8 x 0.0 LONG 469 4 9 MOTOR STNDOFF 469 1 81 ELOW MLE 1/ NPT PIPE 864 1 8 IR CONTROL VLVE SSEMLY SEE PGE 9 1 8 MLE HEX NIPPLE 1/4" - 1/8" 490 1 84 SHUTTLE VLVE 444 1 88 HOSE CLMP 88 89 HOSE 4196 1 90 FILTER/LURICTOR SSEMLY G SEE PGE 11 1 91 HOSE- PUSH LOK 6964R 11 9 NYLON TUING S6961 19 9 NTI-FREEZE LUE 184 1 9 MLE ELOW 1/4" TUE 6894 96 FILLER PLUG 681 1 4
Pump ssembly PRT # 46SS (PUMP SM G) SECTION - 1 0 IN*LS. 4 10 IN*LS 9 4 9 4 48 10 8 16 6 4 8 0 IN*LS. 8 6 1 16 44 4 4 8 1 90 IN*LS. 1 1 1 11 IN*LS. 0 10 IN*LS 90 IN*LS. 14 10 IN*LS 19 0 IN*LS. SECTION - 44 9 18 44 0 1 IN*LS. 0 1 IN*LS. 41 49 49 0 1 IN*LS. 90 IN*LS. 0 1 IN*LS. 4 90 IN*LS. 10 IN*LS. 1 46 10 IN*LS. 1 90 IN*LS. IN*LS. 0 10 IN*LS 1 IN*LS. 1 IN*LS. 90 IN*LS. 1 90 IN*LS.
Pump ssembly PRT # 46SS (PUMP SM G) ITEM # DESCRIPTION PRT # QTY 1 PUMP ODY G 40 1 ERING ROLLER /8x1/16x/8 WIDE 6860 1 THRUST ERING 660 1 4 THRUST WSHER 6644 ECCENTRIC SHFT SM /8" G 480SS 1 6 THRUST ERING 66106 1 THRUST WSHER 66108 8 ECCENTRIC SHFT DPTER G 4908 1 9 O-RING 1 /4 X 1 /8 6001 1 10 RETINING RING 6898 1 11 POW'R UD DUMP PLUG 48 1 1 O-RING /16X/16 60008 1 CKUP WSHER 608008 1 14 MLE TEE 1/8" PIPE TO 1/4" TUE 446 1 1 PIPE PLUG 1/4" FLUSH W/ COTING 4609 1 16 UNLODING PISTON SSEMLY 466SS 1 MLE ELOW 1/4" TUE 1/4" PIPE 499 1 18 LL 1/8" 90906 19 G PISTON LOCK TUE 4648 1 0 OUTLET TUE PISTON LOCK 481 1 1 LL /16" 9101 UNLODING SPRING 461 1 DJUSTING SCREW G 490 1 4 O-RING /8X/4 URETH 60016 1 PIPE PLUG FLUSH 1/16 W/ COTING 40049 OTTOM PLTE 4900 1 8 GER SET 9/ 48S 1 9 SHFT-IDLER 6880 1 0 SCREEN 6891 1 1 TUE-GUIDE.11 68894 SHCS 1/4-8 X 1 /4 68 PLTE-SCREEN MTG. 689 1 4 MLE ELOW 1/8 PIPE 694 1 SPRING 68 6 ROLL PIN 1/8 X /4 LONG 98 1 LL STOP G 4904 8 GSKET 9/64 X /8 8669 9 SPRING CP UNLODING VLVE 46 1 41 TUE RETURN 6869 1 4 ERING ROLLER 1 1/4x1 1/x/4 WIDE 6600 1 44 ERING ROLLER 1/x11/16x1/ WIDE 68891 4 RING-RETINING 6889 1 46 PIPE PLUG 1/8" FLUSH W/ COTING 4608 1 4 CRT REL. VL. SSEMLY 660SS 1 48 SHFT SEL G 490 1 49 PISTON LOCK SM. G-SERIES 0." 466SS 0 SHCS /16-4 X 1. 699 8 6
Pump Sub ssembly PRT# 4644SS (GUGE SHROUD SSM) ITEM# DESCRIPTION PRT# QTY 1 GUGE SHROUD 4690 1 GUGE TORQUE WRENCH W/ FLNGE 469 1 FEMLE CONNECTOR 1/4 NPT-1/8 TUE 46106 1 4 HCS 10-4X.0 16SS 449 U-STYLE NUT 10-4 46 6 GUGE TUING TORQUE WRENCH 4698 1 MLE FITTING 1/4" NPT TO 1/8" TUE 469 1 PRT# 466SS (UNLODING PISTON SM. ) ITEM # DESCRITPION PRT # QTY. 01 UNLOD PISTON 46 1.00 0 O RING 1/4X/8 60009 1.00 0 CK-UP WSHER TEF 468 1.00 04 DOWEL PIN 1/8X/4 LG 4686 1.00 PRT# 466SS (PISTON LK SM. ) ITEM # DESCRIPTION PRT # QTY 1 PISTON LOCK G 49 1 LL 1/8" 90906 SPRING 6604 1 4 LL STOP 68810 1 LL RETINER 6604 1 6 INTKE SET 66046 1 GSKET /64X19/ 86 1 8 PLUG PISTON LOCK 688 1 9 GSKET 9/64 X /8 8669 1 10 DPTOR. DI. 68909 1 11 SPRING, PISTON 6840 1 1 PISTON. DI. 68 1 400 IN*LS. 1 11 10 1 00 IN*LS. 8 9 4 6 IN*LS. 10 IN*LS.
Valve ssembly PRT#469SS (IR SOLENOID 4W/P) HYDRULIC SCHEMTIC P T P T 0 IN*LS. 1 11 14 1 0 IN*LS. 16 4 PLCES IN*LS. 4 4 PLCES 10 6 19 10 IN*LS. 9 9 8 6 IN*LS. ITEM# DESCRIPTION PRT # QTY 1 ODY-VLVE 6808 1 SLIDER DV/RET ONLY 448 1 LL /16" 9048 4 4 SET SCREW 1/4-8 X 1/4 CUP 404 4 IR CYL SM 4194SS 1 6 O-RING /X11/ 60009 CK UP WSHER 6891 8 SHER SEL 688 9 SPRING 6884 10 O-RING /8 X /4 6008 1 11 ERING ROLLER /16x1/x/16 WIDE 688 4 1 PIN ERING 6890 1 SET SCREW /16-18 X 1/4 CUP 94418 1 14 SHCS #10- X 1" LG PLTED 6864 1 VLVE TOP PLTE MCHINED 46 1 16 SHCS #10-4 X." 4199 4 1 O-RING /16X/16 60008 1 18 LL 1/4" 949 1 19 VLVE PLUG POSITION SLIDER 461 1 6 O-RING SE PORT #10 60910 1 SPRING 6811 1 9 SPCER VLVE SLIDER 46418 1 1 O-RING /16X/16 URE 60011 4 1 18 1 1 84-108 IN*LS. 1 8
Valve Sub ssembly PRT# 4644SS (IR CONTROL VLVE SSM.) ITEM # DESCRIPTION PRT # QTY 1 IR CONTROL VLVE 1/" PORTS 4969 1 1/"STRIGHT SWIVEL 496 1 SWIVEL DP 1/8 90 480 1 4 PIPE DP 1/-1/8 4 1 MLE RUN TEE 1/ 48 1 6 HOSE R 1/" NPT TO 1/" TUE 4990 1 1/8 SWIVEL TEE 4968 8 SWIVEL NUT ELOW 696 9 1/" NPT HEX HED PIPE PLUG 4611 1 1 P 4 1 9 6 8 PRT# 6896SS (VLVE DPT ) ITEM# DESCRIPTION PRT# QTY. 1 VLVE DP 880 1 -U RING 6881 O-RING /8X1/ 6001 1 PRT# 4194SS (IR CYL SSM ) ITEM # DESCRIPTION PRT # QTY 1 ODY IR CYL 444 1 O-RING 1/8 X 1/4 60006 1 O RING 1/4X/8 60010 1 4 IR CYLINDER PISTON 44 1 SPRING IR CYL 449 1 END CP 4196 1 8 O-RING 1 1/16X1 /16 600 1 9 SEL 6849 1 10 O-RING 11/16X1/16 6001 1 11 O-RING SE PORT #10 60910 1 1 PUSH PIN IR VLVE 446 1 1 OVERRIDE PIN 4198 1 14 E-RING 1/4" SHFT 40 1 1 SPRING PLTE IR VLV 448 1 9
Manifold ssembly (469SS) MNIFOLD SM. ITEM # DESCRIPTION PRT # QTY. 01 VLVE MNIFOLD 460 1.00 0 CRTRIDGE RELIEF VLVE 44 1.00 0 1/16 PIPE PLUG-FLUSH 40049.00 04 PIPE PLUG 1/8" FLUSH 8109.00 0 PIPE NIPPLE 1/8 NPT 6891 1.00 06 PIPE COUPLING 1/8 68918 1.00 0 INT.RELIEF SM HF 68999SS 1.00 (68999SS) INT. RELIEF SM. ITEM # DESCRIPTION PRT # QTY. 01 CRTRIDGE 66096 1.00 0 CONE REL VLVE 66086 1.00 0 POPPET RELIEF SPRING 44641 1.00 04 RELIEF VLVE DJUSTING SCREW 6608 1.00 0 HEX NUT /16-0 6890 1.00 10
Filter Lube ssembly PRT# 464SS (FILTER LURICTOR) ITEM # DESCRIPTION PRT # QTY 1 FILTER/LURICTOR RCKET 469 1 IR FILTER 8641 1 IR LURICTOR 864 1 4 HOSE R ELOW 1/" NPT TO 1/" TUE 4991 1 11
Pendant ssembly PRT# 6899SS (PENDNT SSM.) ITEM# DESCRIPTION PRT # QTY 1 PENDNT ODY 41968 1 IR PEND. LOCK MOD. 6896 1 CRTRIDGE-IR 4196 4 SWIVEL DP 1/8 481 LL / 606961 6 RETINING-RING 68808 CRTRIDGE CP 4190 1
Reservoirs (4996P) 1. GLLON RESERVIOR (461P). GLLON RESERVIOR 4 8 9 Series G 1 hp 1/ 1,1 Kw 460 6 10 1. GLLON RESERVOIR NOTE: THIS ILLUSTRTION IS FOR REFERENCE ONLY. THE PPERNCE OF YOUR UNIT MY DIFFER FROM UNIT SHOWN. ITEM # DESCRIPTION 1. GLLON. GLLON QTY. 0 RESERVOIR 4996P 461P 1.00 04 RESERVOIR GSKET 8469 8469 1.00 0 RETHER VENT /8" NPT 4648 4648 1.00 06 PIPE PLUG 4669 4669 1.00 0 SE #1 HEX PLUG WITH PORT 46118 46118 1.00 08 HHCS 1/4-0 x /4 LG PLTED 6891 6891 14.00 09 SELING WSHER 689 689 14.00 10 G RESERVOIR DECL 460 460 1.00 SIGHT GUGE 46009 46009 1.00 COVER PLTE 464 4644 1.00 NOTE: LL RESERVOIRS RE POWDER COTED LCK 1
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