Simplex G6 Series Service manual

G6 GAS
POWER PUMPS
Reference # - TD072
Rev. - A
Date - 0910
2525 GARDNER ROAD, BROADVIEW, IL 60155
1.800.323.9114 • Outside U.S. 1.708.865.1500
www.tksimplex.com
- Note -
SIMPLEX has taken every care in preparing this Operational Manual that is intended as a technical guideline only.
SIMPLEX accepts no liability in relation to any use or reliance made of any information in this Operational Manual.
All information, illustrations and specications in this Operational Manual are based on the latest information
available at the time of publication. The right is reserved to make changes at any time without notice.
Equipment operators and installers shall be responsible for ensuring that a safe working environment and safe
systems of work are in place before operating the equipment.
©2010 SIMPLEX
CONTENTS
Recieving Instructions and Warranty Statement .........................................................................................................2
Safe and Correct Use ............................................................................................................................................... 2-3
Technical Specifications ...............................................................................................................................................3
Working Pressure .........................................................................................................................................................3
Install Vent Plug ............................................................................................................................................................3
Adding Oil .....................................................................................................................................................................3
Install Hydraulic Connections .......................................................................................................................................4
Gasoline, Motor & Fuel .................................................................................................................................................4
Pump Mounting ............................................................................................................................................................4
Control Valves ...............................................................................................................................................................5
Starting the Pump for the First Time ............................................................................................................................5
Adjusting the External Relief Valve ...............................................................................................................................5
Jacking Safety ..............................................................................................................................................................6
After Completing the Job .............................................................................................................................................6
Periodic Maintenance ...................................................................................................................................................6
Maintain Oil Level .........................................................................................................................................................6
Clean Oil Intake Screen ................................................................................................................................................6
Flushing the Pump .......................................................................................................................................................7
Problem / Cause - Solutions ........................................................................................................................................7

••• 2 •••
IMPORTANT - READ CAREFULLY
This manual contains important information for the correct installation, operation and maintenance of this
equipment. All persons involved in the installation, operation and maintenance of this equipment must be
thoroughly familiar with the contents of this manual. To safeguard against the possibility of personal injury or
property damage, follow the recommendations and instructions of this manual. Keep this manual for reference.
WARRANTY STATEMENT
SIMPLEX products are warranted to be free of defects in materials and workmanship under normal use for
as long as the original purchaser owns them, subject to the guidelines and limitations listed. This warranty does
not cover: normal wear & tear, cosmetic items, abuse, overloading, alterations, improper fluid, or use in a
manner for which they are not intended. If the customer believes a product is defective, the product must be
delivered, or shipped freight prepaid, to the nearest SIMPLEX Authorized Service Center for evaluation and
repair.
1.0 RECEIVING INSTRUCTIONS
Important! Make sure to inspect all of the components for shipping damage. If damage is found, notify carrier at
once. Shipping damage will not be covered by warranty. The carrier is responsible for all loss associated with
shipping damage.
2.0 SAFETY
Make sure to read the instructions, warnings and precautions carefully. Follow any recommended safety precautions
to avoid personal injury or damage to the unit. Simplex cannot be responsible for any damage or injury from unsafe
use, lack of maintenance or incorrect operation. In the event any questions or concerns arise, contact SIMPLEX or a
local Distributor for clarication.
The pump’s maximum working pressure is 10,000 PSI (700kg/cm2). Make sure that all hydraulic equipment such as
rams, hoses, etc. used with this pump are rated at 10,000 PSI (700kg/cm2) operating pressure.
If you have never been trained on high-pressure hydraulic safety, consult your distributor or service center for a free
Simplex Hydraulic Safety Course.
Failure to comply with the following cautions and warnings could cause equipment damage, property damage or
personal injury.
DANGER is only used when your action or lack of action may cause serious injury or even death.
WARNING indicates a potential danger that requires correct procedures or practices to avoid personal injury.
CAUTION is used to indicate correct operating or maintenance procedures and practices to prevent damage
to, or destruction of equipment, or other property.
WARNING: Wear proper personal protective gear when operating hydraulic equipment.
WARNING: Stay clear of loads supported by hydraulics. A cylinder, when used as a load lifting device unless it was
designed for that purpose. It should never be used as a load holding device. After the load has been raised or
lowered, it must always be blocked mechanically.
WARNING: USE ONLY RIGID PIECES TO HOLD LOADS. Carefully select steel or wood blocks that are capable of
supporting the load. Never use a hydraulic cylinder as a shim or spacer in any lifting or pressing application.
G6 Series Gas Power Pumps

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••• 3 •••
DANGER: To avoid personal injury, keep hands and feet away from cylinder and work-piece during operation.
WARNING: Do not exceed equipment ratings. Never attempt to lift a load weighing more than the capacity of the
cylinder. Overloading causes equipment failure and possible personal injury. The cylinders are designed for a
maximum pressure of 10,000 PSI (700kg/cm2). Do not connect a jack or cylinder to a pump with a higher pressure
rating. Never set the relief valve to a higher pressure than the maximum rated pressure of the pump. Higher settings
may result in equipment damage and/or personal injury.
WARNING: The system operating pressure must not exceed the pressure rating of the lowest rated component in
the system. Install pressure gauges in the system to monitor operating pressure. It is your window to what is
happening in the system.
CAUTION: Avoid damaging hydraulic hose. Avoid sharp bends and kinks when routing hydraulic hoses. Using a
bent or kinked hose will cause severe back-pressure. Sharp bends and kinks will internally damage the hose, leading
to premature hose failure.
Do not drop heavy objects on hose. A sharp impact may cause internal damage to hose wire strands. Applying
pressure to a damaged hose may cause it to rupture.
IMPORTANT: Do not lift hydraulic equipment by the hose or swivel couplers. Use the carrying handle or other means
of safe transport.
CAUTION: Keep hydraulic equipment away from ames and heat. Excessive heat will soften seals, resulting in uid
leaks. Heat also weakens hose materials. For optimum performance do not expose equipment to temperatures of
65° C (170° F) or higher. Protect hoses and cylinders from weld spatter.
DANGER: Do not handle pressurized hoses. Escaping oil under pressure can penetrate the skin, causing serious
injury. If oil is injected under the skin, see a doctor immediately.
DANGER: Only use hydraulic cylinders in a coupled system. Never use a cylinder with unconnected couplers. If the
cylinder becomes severely overloaded, components can fail catastrophically causing severe personal injury or death.
3.0 TECHNICAL SPECIFICATIONS
G6 Gas Series
Operating Pressure 10,000 PSI (700kg/cm2)
Motor Rating 5.5 hp Honda Gasoline Engine
Flow Rate 750 cu. in./ min. @ 1,200 psi, 100 cu. in / min. @ 10,000 psi
Maximum Operating Temperature 170 F - (65 C)
4.0 WORKING PRESSURE
The pump’s maximum working pressure is 10,000 PSI (700kg/cm2). Make sure that all hydraulic equipment such as
rams, hoses, etc. used with this pump are rated at 10,000 PSI (700kg/cm2) operating pressure.
4.1 INSTALL VENT PLUG
Remove SHIPPING PLUG (A) and install VENT PLUG (B) into cover plate.
4.2 ADDING OIL
Remove OIL FILLER CAP (C) and add SIMPLEX Hydraulic Oil into reservoir.
Oil level should not exceed 1” from the reservoir cover.
*As a “rule of thumb” oil should be visual in site window when the unit is
powered down and all connected tools or cylinders are retracted.
A
C
B

••• 4 •••
4.3 INSTALL HYDRAULIC CONNECTIONS
Use only cylinders, tools, hoses and
accessories rated at 10,000 PSI (700kg/cm2). Remove the
shipping plugs from the ports to connect your coupling(s)
or hose(s) to manifold. Use 1.5 wraps of Teon tape (or suit-
able thread sealant) on all threads, leaving the rst com-
plete thread free of tape to ensure no foreign matter enters
the hydraulic circuit.
When making connections with quick
disconnect couplings, make sure the couplings are fully
engaged. Threaded connections such as ttings, gauges,
etc. must be securely
tightened and leak free.
WARNING: Loose or improperly threaded
ttings can be potentially dangerous if
pressurized; however, severe over tightening can cause premature thread failure. Fittings need to be tightened se-
cure & 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.
CAUTION: Do not subject the hose to potential hazards such as sharp surfaces, extreme heat or heavy impact. Do
not allow the hose to kink or twist. Inspect each hose for wear before it is used.
4.4 GASOLINE MOTOR & FUEL
1. Above 32 Fahrenheit, use SAE 10 W 30 (Motor Only)
2. Below 32 Fahrenheit, use SAE 5 W 20 (Motor Only)
3. Oil sump cpacity - About 1.3 pints or check dip stick.
4. Use clean, unleaded automotive gasoline (without alcohol).
4.5 PUMP MOUNTING Refer to the chart for mounting dimensions to secure the pump to a xed surface.
2.5 gal.(10L) 5 gal. (20L) 10 gal. (38L)
A17 19.6 19.6
B2.75 4.69 4.69
C4.37 5.03 5.03
D1.93 2.93 2.93
E9.75 11.75 11.75
F1/4-20unc
(4 places)
1/4-20unc
(4 places)
1/4-20unc
(4 places)
3 Way Solenoid Valve 4 Way Solenoid Valve
2 Way Manual 3 Way Manual 4 Way Manual
"A"
Port
"B"
Port
"A"
Port
"T"
Port
"A"
Port
"B"
Port
"A"
Port
"T"
Port
"A"
Port
"T"
Port
A
BC
D
E
F

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••• 5 •••
5.0 CONTROL VALVES
2-Way Valve for Single Acting Rams
• To Advance......turn lever to the right.
• To Hold......turn motor off and leave in
advance position.
• To Retract......turn lever to the left.
3-Way Manual Valve for Single Acting Rams
• To Advance......push lever to the right.
• For Neutral/Hold......place lever in the middle.
• To Retract......push lever to the left.
4-Way Manual Valve for Double Acting Rams
• To Advance......push lever to the right.
• For Neutral/Hold......place lever in the middle.
• To Retract......push lever to the left.
5.1 STARTING THE PUMP FOR THE FIRST TIME
• Place “hydraulic control valve” in neutral (center position).
• Place throttle to choke position (extreme right). Grasp “starter handle” and pull rope out slowly to engagement.
• Pull rope with a rapid, continuous full stroke and let rewind slowly, avoiding it snapping back.
• Move the control lever to “high speed” position, then to “run” as the engine warms.
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
cylinders should be inverted and double-acting on their side with the hydraulic couplers pointed up. When the
trapped air is removed from the hydraulic circuit, the cylinder will advance and retract smoothly. Sluggish or jerky
cylinder action is usually the rst sign of air in the system.
Shift the lever to Advance position to activate ram or cylinder. To hold load, place lever into Neutral/Hold or turn off
pump. Move lever to retract position to release load.
CAUTION: Never operate the pump at 10,000 PSI (700kg/cm2) without ram movement for more than 1 minute
without shifting the control valve to neutral or turning off motor. Leaving the valve in the advance or retract position
without the piston rod moving will overheat the oil.
CAUTION: Never disconnect or connect any hydraulic hoses or ttings without rst 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.
5.3 ADJUSTING THE EXTERNAL RELIEF VALVE
Pumps are preset at 10,000 PSI (700kg/cm2). To re-adjust or lower the maximum operating pressure, follow these
steps below.
1. Install gauge and gauge adapter between pump and cylinder.
2. Remove Acorn Nut to expose adjusting screw.
3. Place valve lever in Neutral/Hold position and start motor.
4. Move lever to direct pump output to pressure port (Advance).
5. Insert 7/32 Allen wrench into adjusting screw in the hole on the left side of
valve.
6. Turn adjusting screw clockwise to increase, or counter clockwise to
decrease pressure.
7. Do not exceed 10,000 PSI (700kg/cm2).
8. Check valve setting by shifting the valve to advance and retract cylinder
several times.
9. Maximum gauge reading should remain constant.
High Pressure Relief
Adjustment Location

••• 6 •••
5.4 JACKING SAFETY
Know the weight you intend to lift and select a cylinder with enough capacity to provide the appropriate factor of
safety. Appropriate factors of safety vary with the type of load to be lifted and number of lifting points. Prepare a
lifting plan that accounts for potential changes in load factors such as; load shift, center of gravity, and stability.
Choose a cylinder with at least 10% more capacity than is required by the lifting plan.
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 (ASME ANSI B30.1).
5.5 AFTER COMPLETING THE JOB
Before disconnecting hoses, ttings, etc., rst be sure the ram is unloaded and retracted, then unplug the power
cord and shift the hydraulic controls several times to release system pressure. Store the pump in a clean, dry area.
6.0 PERIODIC MAINTENANCE
Completely change the hydraulic oil and clean the intake screen and magnet (located in the reservoir) twice a year. If
equipped, change the external oil lter twice a year (Use Simplex oil only, Model # AO1, 1 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 may void the pump’s warranty.
The following conditions require more frequent oil changes.
• Rigorous duty, where oil temperature may reach 150°F.
• High humidity environment and extreme changes in temperature that can result in condensation inside the
reservoir.
• Dirty or dusty environments that may contaminate the oil.
• Frequent connection and disconnection of hydraulic hoses and components.
WARNING: The electrical power cord must be disconnected from the electrical outlets before performing
maintenance or repair procedures.
6.1 MAINTAIN OIL LEVEL
Check hydraulic oil level every 30 hours of operation (sight gauge should be completely covered in oil when all tools
are retracted. Add Simplex oil (Model # AO1 – 1 gallon) when necessary. Oil level should be no more than 1” from
top of reservoir plate – with cylinders retracted and motor off.
6.2 CLEAN OIL INTAKE SCREEN ONCE A YEAR
Loosen and remove reservoir plate bolts. Lift pump unit off the reservoir, being care-
ful not to damage the gasket.
Applies to 2.5 gallon reservoirs:
Remove the 5 Allen socket head cap screws securing the screen to the 1st stage
gear pump. Care should be taken not to remove the center plate and gears. Remove
and clean with nonammable solvent, blow dry clean. Reinstall in reverse order and
torque bolts to 75 inch pounds. Keep the motor and pump as clean as possible.
Applies to the 5 and 10 gallon reservoirs:
Unscrew screen from bottom of pump unit and clean with nonammable solvent. Blow dry and reassemble. Keep
areas around pump unobstructed to provide good air ow around the motor and pump. Keep the motor and pump
as clean as possible.
Oil Fill (1.5 - 10 Gal. Models)
Sight Gauge
Drain Plug (1.5 - 10 Gal.)

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••• 7 •••
6.3 FLUSH THE PUMP
If you suspect your pump has been contaminated or discover sludge or other deposits on internal components, you
should thoroughly ush the pump. Remove the old oil from the reservoir, then thoroughly clean the reservoir and rell
with a clean, nonammable ushing oil. Reassemble the pump and motor to the reservoir.
Now run the pump in no load condition for 1 or 2 minutes maximum. Unplug the pump and remove the motor and
pump assembly again. Now drain the ushing oil and re-clean the inside of the reservoir. (Make sure ushing uid is
also drained from pump assembly). Rell the reservoir with Simplex hydraulic oil and reassemble the pump.
7.0 TROUBLESHOOTING
PROBLEM CAUSE-SOLUTION
Sporadic Cylinder Action: • Air in the hydraulic system. Bleed the hydraulic circuit.
• Check reservoir oil level.
Motor Will Not Start: • Have motor checked for proper operation.
• Check manufacturers operating instructions.
Noisy Operation: • Air in system.
• Be sure the oil reservoir is lled to normal level.
• Check all points where air might leak into system.
• Clogged or blocked intake screen.
Pump Oil is Over Heating: • Inspect for high pressure leakage at the pump (leaking at plug or
relief valve).
• Oil level is low. Fill reservoir to normal level, or retrot the pump with
larger reservoir.
Pump Runs But Will Not Pump Oil: • Pump is not primed. Run pump a few minutes tipping from side to
side.
• Inspect to make sure that external adjustable relief valve is set
properly.
• Defective control valve, take to nearest Simplex Authorized Service
Center for repair.
• Incorrect motor rotation, take to nearest Simplex Authorized Service
Center for repair.
• Check to make sure the intake screen is not clogged. Clean if
needed.
• Check oil reservoir is low. Fill as needed.
• Oil viscosity is too high. Replace with SIMPLEX oil.

UNITED STATES HOME
OFFICE AND FACTORY
2525 Gardner Road
Broadview, IL 60155-3719
Phone: [phone]
Fax: [phone]
Toll Free: [phone]
Email: [email protected]
www.tksimplex.com
CANADIAN WAREHOUSE
637 McCaffrey
St. Laurent, PQ H4T1N3
Phone: [phone]
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Toll Free: [phone]
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Lindelaufer Gewande 24A
6367 Az Voerendaal,
Netherlands
Phone: [phone]
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Email: [email protected]
www.tksimplex.nl
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Phone: [phone]
Fax: [phone]
Email: [email protected]
MEXICO
Phone: [phone]
Fax: [phone]
[email protected]
SOUTH & CENTRAL AMERICA
[email protected]
MIDDLE EAST
Phone: [phone]
Fax: [phone]
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SOUTH AFRICA
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Printed in the U.S.A.
2525 GARDNER ROAD, BROADVIEW, IL 60155
1.800.323.9114 • Outside U.S. 1.708.865.1500
www.tksimplex.com
SIMPLEX PRODUCTS ARE WARRANTED TO BE FREE OF DEFECTS IN MATERIALS AND WORKMANSHIP UNDER NORMAL USE FOR AS LONG AS THE
ORIGINAL PURCHASER OWNS THEM, SUBJECT TO THE GUIDELINES AND LIMITATIONS LISTED. THIS WARRANTY DOES NOT COVER : NORMAL
WEAR AND TEAR, COSMETIC ITEMS, ABUSE, OVERLOADING, ALTERATIONS. IMPROPER FLUID, OR USE IN A MANNER FOR WHICH THEY ARE NOT
INTENDED. IF THE CUSTOMER BELIEVES A PRODUCT IS DEFECTIVE, THE PRODUCT MUST BE DELIVERED, OR SHIPPED FREIGHT PREPAID, TO THE
NEAREST SIMPLEX AUTHORIZED SERVICE CENTER FOR EVALUATION AND REPAIR.