Simplex PAM Series Installation and operation manual

Operating & Maintenance Instructions
For 11/2 H.P. Air & Gasoline Pumps
and 8 H.P. Gasoline Pump.
AIR & GASOLINE POWER PUMPS
PRO - MAG
40 & 50 SERIES
PAM & PGM SERIES
The world's most complete line of industrial, hydraulic and
mechanical lifting and positioning equipment.
SIMPLEX DIVISION OF TEMPLETON, KENLY & CO., INC.
2525 Gardner Road • Broadview, Illinois 60155 • [phone] / Fax [phone]
www.tksimplex.com
HYDRAULIC & MECHANICAL POWER
Part Sheet #: 54393
Revised: 12-01
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SINCE - 1899
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1.5 H.P. Air Pumps
3.5 and 8 H.P.
Gas Pumps

SAFETY
1-1. Working Pressure
The pump's maximum working pressure is 10,000 PSI (700 kg/cm2). Make sure
that all hydraulic equipment used with this pump are rated at 10,000 PSI operat-
ing pressure.
1-2. Hydraulic Connections
Never disconnect or connect any pressurized hydraulic hoses or fittings. 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 re-
leased.
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 pressur-
ized, 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 connec-
tions 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.
1-3. Electrical Power for Solenoid valves (normally 12 or 24 volts)
1. CHECK FOR PROPER ELECTRICAL SUPPLY BEFORE CONNECTING.
2. 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. Solenoids 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.
1-4. Jacking Safely
You must know the weight of what you intend to lift and choose a ram with at least 10%
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 mul-
tiple 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 B30.1).
!
- 2 -

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.
2-1. Electrical Connections: Solenoid valves only.
Air Connections for AIR POWER PUMPS: Use only clean, dry, well lubricated air.
Gasoline Motor Oil and Fuel:
1. Above 32 degrees Fahrenheit use S.A.E. 10 W 30 (Motor only )
2. Below 32 degrees Fahrenheit use S.A.E. 5 W 20 (Motor only )
3. Oil sump capacity - -About 1.3 pints or check dip stick
4. Use clean, unleaded automotive gasoline ( without alcohol )
2-2. 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 2" from top of reservoir
plate -- with cylinders retracted and motor off. Add Simplex oil as necessary. Do not
mix different grades of oil, or types of oil.
Make sure all desired gauge, valve, hose and quick coupler connections are tight and
secure before operating (See Section 1.2). The pumps pressure ports are 3/8 NPTF and are
located just below the control valve. (See Section 3-1).
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.
2-3. Starting instructions ( Gasoline Motor )
• Hydraulic control valve in neutral ( center position ): • 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, and do not allow to snap back. • Move
the control lever to "HIGH SPEED" position then to "RUN" as the engine warms.
INSTRUCTIONS BEFORE USE
- 3 -

OPERATING INSTRUCTIONS AT A GLANCE
Before Operating Pump:
1. If your pump is equipped with a SIMPLEX SOLENOID be sure the electrical connection
is grounded. Check that your power supply agrees with the requirements of the sole-
noid.
2. Use only cylinders, hoses and equipment rated at 10,000 PSI.
3. Make sure all hose and fitting connections are tight and secure. Hoses cannot be
kinked or twisted.
4. Oil level should be 1 to 2" from the top of the reservoir plate, with cylinders retracted
and motor off.
5. Never operate the pump with the directional control valve in advance or retract at
10,000 PSI without ram movement for more than 1 minute. Leaving the valve in the
advance or retract position without the rams piston rod moving will overheat the oil.
After Completing the Job:
1. 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.
2. Store the pump in a clean, dry area.
Periodic Maintenance:
1. 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 # 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 voids the pumps warranty.
2. Contact an AUTHORIZED SIMPLEX SERVICE CENTER if there are any problems with
the equipment.
- 4 -

* Useable 3/8 NPTF port
*
* A
* A
* A
* A
B *
B *
Return ports
only.
(Marked T)
OPERATION
3-1. Control Valves:
a. 2-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.
b. 3-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.
c. 4-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.
3-2.. 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.
3-3. 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.
3-4. 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.
3-5. Never operate the pump at 10,000 PSI without ram movement for more than 1 minute without
shifting the control valve to neutral. Leaving the valve in the advance or retract posi-
tion without the piston rod moving will overheat the oil.
- 5 -

MAINTENANCE
WARNING: THE ELECTRICAL POWER CORD MUST BE DISCONNECTED FROM ELEC-
TRICAL OUTLETS BEFORE PERFORMING MAINTENANCE OR REPAIR
PROCEDURES.
4-1. Maintain Oil Level -- check hydraulic oil level every 30 hours of operation. Add Simplex oil
(Model # AO1 -- 1 gallon) when necessary. Oil level should be no more than 2" 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 140 F.
b. High humidity environment and extreme changes in temperature that can result in con-
densation inside the reservoir.
c. Dirty or dusty environments that may contaminate the oil.
4-2. 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.
4-3. Keep areas around pump unobstructed to provide good air flow around the motor and pump.
Keep the motor and pump as clean as possible.
4-4. 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 10,000 PSI.)
e. Check valve setting by shifting the valve to advance and retract cylinder several times.
Maximum gauge reading should remain constant.
4-5. 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 1 or 2 minutes maximum.
d. Unplug the pump and remove the motor and pump assembly again. Now drain the flush-
ing 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.
- 6 -

TROUBLESHOOTING
Sporadic Cylinder Action
Motor Will Not Start
Noisy Operation
Pump Oil is Over Heating
Pump Runs but Will Not Pump Oil
1. Air in the hydraulic system. See Sec. 3-3 for
correct bleeding procedure.
2. Check reservoir oil level.
Check manufacturer's operating instructions.
1. Air in system. (See Sec. 3-3 for bleeding
procedure).
2. Be sure the oil reservoir is filled to normal level.
3. Check all points where air might leak into
system.
1. Oil viscosity too high. Replace with Simplex #9.
2. Check for high pressure leakage on upper
pressure plate. (Leaking at plug).
3. Oil level is low. Fill reservoir to normal level, or
refit the pump with larger reservoir.
4. (See Section 3-5)
1. Pump is not primed. Run pump a few minutes
tipping from side to side.
2. Check to make sure that externally adjustable
relief valve set properly.
Check internal relief valve.
3. Damaged O-Rings. Take to nearest Simplex
service center for repair.
4. Defective control valve. (Troubleshoot
separately).
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 Cause -- Solution
- 7 -

46
21 35 36 37
38
15
25
16 46 14
18
43 3811 12 13 10 9 42 1
8
76
534
55
53
54
2
31
26
27
28
30
33
32
18
44
29
45
2019
18
17
23
24
22
25
21
41
34
50
49
48
47
18948
PUMP ASSEMBIES 40 SERIES GAS PUMP
- 8 -

DISCRIPTION
Retaining Ring
PIpe Plug
Ext. Relief Seat
Ext. Relief Cone
Valve Relief Spring
Adjust Screw
Piston Block Assm.
SHCS 5/16-24 X 2
Screw
QTY.
1
2
1
1
1
1
1
2
2
ITEM
45
46
47
48
49
50
53
54
55
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
41
42
43
44
PART NO.
68892
81093
68004
68003
66085
66083
68502
82892
82687
DISCRIPTION
2 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 .225 Dia.
Piston .225 Dia
Piston Spring
Ball Stop
1/4 Socket Pipe Plug
Piston Unloading Assm.
Ball Retainer
803C-7D Ball Bearing
Intake Seat
Tube Assm.
R102-10B Ball Bearing
Spring
Set Screw
Nut-Hex Jam
Soc Pipe Plug Steel
Center Plate .11
Bottom Plate
Gear Pump
Shaft-Idler
Screen
Guide Tube
Screw
Plate-Screen Mount
Screw
Spring
Roll Pin 1/8 x 15/16
Ball Stop Screw
Gasket
Return Tube
Backup Washer
Spring
Bearing
PART NO.
68507
68360
66033
66474
68906
66106
66108
68829
56020322
68978
68945
67868
68340
68810
93950
68535
66043
90906
66046
68851
91701
68981
68242
68920
97641
68848
68849
68883
68850
68921
68894
68255
68927
89148
68225
81332
68226
85726
68569
69513
66042
68891
QTY.
1
1
1
2
1
1
1
1
2
1
1
1
1
1
1
1
1
5
1
1
2
1
1
1
2
1
1
2
1
1
2
4
1
1
1
1
1
2
1
2
1
3
18948
PUMP ASSEMBIES 40 SERIES GAS PUMP
- 9 -

46
21 35 36 37
38
25
15 16 46 14
18
43 3811 12 13 10 9 42 1
8
7
9 42
6
534
55
53
54
2
31
26
27
28
30
33
32
18
44
29
45
20
19
18
17
23
24
22
25
21
41
34
50
49
48
47
For 5 & 10 Gallon Reservoir.
56
57
58
18721
PUMP ASSEMBIES FOR 40 SERIES AIR PUMP
- 10 -