The Simplex ES - Series

POW'R - RISER
100 TON
Operating & Maintenance Instructions

• Capacity 100 Tons

• Height Closed/Ext. 25 1/2" / 40 1/2"
• Weight 458 lbs.

FEATURES AND BENEFITS

•More rapid advance & Retract •Quieter - 81 Decibels
•Double acting Hydraulic cylinder •Gage port included
(Heavy Duty Design) with 4-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 5-94
The world's most complete line of industrial, hydraulic and
mechanical lifting and load-holding equipment.
SIMPLEX DIVISION OF TEMPLETON, KENLY & CO., INC.
2525 Gardner Road • Broadview, Illinois 60155 • (708) 865-1500 / Fax (708) 865-0894
 CONTENTS

Maintenance at a Glance Page 2

Basic Assembly Instruction Fig. 1 Page 3

Basic Operating Instructions Fig. 2A & 2B Page 4 & 5

Part Sheet - Basic Assembly Fig. 3 Page 6 & 7

Part Sheet - Basic Sub-Assembly Fig. 4 Page 8 & 9

Part Sheet - Pump & Motor Assembly Fig. 5A & 5D Page 10 & 12

Part Sheet - Stand. Cylinder Assembly Fig. 6 Page 13

Part Sheet - Control Valve Assembly Fig. 7 & 7A Page 14 & 15

Part Sheet - Handle Support Fig. 8 Page 16

Part Sheet - Air Motor Fig. 9 Page 17

Part Sheet - Filter Lubricator Fig. 10 Page 18

Part Sheet - 44" Min. Basic Assembly Fig. 11 Page 19 & 20

Part Sheet - 44" Min. Cylinder Assembly Fig. 12 Page 21

Maintenance:
A. Oil Page 22
B. Pump Assembly Page 22 & 23
C. Air Motor Page 23
D. Disassembly Procedure Page 24

Troubleshooting Page 25

1
 POW'R-RISER MAINTENANCE & OPERATING TIPS

1. 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.

2. 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.

3. Normally change the hydraulic oil after every 50 hours of operation or every 90 days,
whichever occurs first.

4. Hydraulic Oil:
• Keep clean
• Don't mix
• Use only Simplex #9

5. Try to protect the piston rod from being struck with tools or other objects. Fully retract
the rod when not in use.

6. Store in a clean, dry area. (Keep the hydraulic oil clean).

7. Adjust the lubrication assembly (#86282, Fig. 10) to 1 or 2 drops a minute, maximum.
The lubricator is filled the an anti-freeze fluid (#18243 - pint), and if needed, should only
be replaced with that fluid. Suitable substitute is Killfrost.

8. 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. 3, Page 3).

2
 1. ASSEMBLY INSTRUCTIONS

The Pow'r-Riser was shipped with the handle assembly (#85465) and the Breather (#30 -
fig. 4 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. 4 - #30 for loca-
tion).
#85464
Handle Support Assembly

#85475
Roll Pin

Hole "B"
Flush-roll pin assembled position
HANDLE ASSEMBLY

1. Slide handle assembly.

(#85465) into handle support
assembly. (#85465) until Hole "A"
Hole "A" lines up with Hole
"B".

2. Drive roll pin (#85475) into #85465

Hole "B" until it is flush with Handle Assembly
handle support assembly
(#85464).

The Pow'r-Riser is now ready for

operation.

Figure 1

3
TO RAISE LOAD: (Refer to Figures 2A and 2B)

1. Pull out knob (item 1) and swing handle assembly (Item 2) up.

2. Place foot on pad (Item 3) and pull out and down on handle assembly (Item 2). 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 9) or by means of eye bolt (Item 11).
Never attempt to pick up jack by handle assembly (Item 2) or swing handles.

3. At the work station, the jack should be positioned on a solid foundation (wooden blocks be-
tween 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.

4. Once the jack has been placed on support blocks, final positioning can be accomplished with
swing down handles (Item 4A & 4B). Handle assembly (Item 2) should be swung down out of
the way prior to jacking.

5. Connect air supply to air valve (Item 5). (1/2 - 14 NPT)

6. Open air valve (Item 5) and move the directional control valve handle (Item 7) to the advance
position.

7. Never allow the jack to run without ram movement for more than 1 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.

8. 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.

9. Place solid stands under the load.

10. Place directional control valve handle (Item 7) in the lower position (see figure 2A) lowering
load onto stands. Place directional control valve handle in neutral position. Close air valve
(Item 5).

TO LOWER LOAD:

11. Open air valve (Item 5).

12. Move directional control valve handle to raise position (see Figure 2A).

13. When load clears stands, place directional control valve handle in neutral position. Remove
stands.

14. Move valve handle (Item 7) to the lower position.

15. When piston has fully retracted, place directional control valve handle in neutral (center) posi-
tion and close the air valve.

4
 AIR MOTOR POWERED POW'R-RISER

11
4B
1 4A
S 5
I 1
M
7
P
Lower Raise
L
10 E
3
X 6

5
2

Figure 2A Figure 2B
 POW'R-RISER BASIC ASSEMBLY

ITEM CONTROL # DESCRIPTION QTY.

1 18333 Load Cap 1
2 18233 Filter/Lubricator Assembly 1
3 85851 Air Shut Off Valve 1
4 88070 Air Pump Assembly 1
5 18139 Hydraulic Oil/5 Gallon
6 87826 Model Decal 1
7 1329901 Pow'r-Riser Basic Assembly 1
8 55701 Hand Grip 2
9 88074 Valve Assembly 1
10 88067 Tube Assembly 1 USE FIG. 3
11 87827 Elbow 1
12 87829 Drain Line 1
13 93582 Soc. Hd. Cap Screw 14
14 85469 Gasket 1
15 18243 Anti-Freeze Lub. 1
16 88111 Caution Decal 1
17 86027 Control Valve Plate 1
18 88120 ES Pow'r-Riser Decal 1

SPECIFICATIONS:

1. Capacity: 100 U.S. Tons @ 9,239 PSI

2. Stroke: 15 Inches
3. Air Pr./Air Vol. Req'd.: 100 PSI/105 SCFM
4. Speed of Piston Travel Under Full Load:
100 PSI: 3 3/4 in./min.
90 PSI: 3 1/4 in./min.
80 PSI: 3 in./min.
5. Reservoir Capacity: 5 Gallons

6
 POW'R-RISER BASIC ASSEMBLY
1

10
5 11
16

1 1/2" to 2"

Oil
Level

FIGURE 3

25.5
Rear Screen Must be
relocated and as-
sembled together along
with the front. Screen at
the assembly before
test. 2
3
S
6 I
18 M 4
P
L 9
E
25.5 Min.
40.5 Max.
X 13

17
7

14

12
26

7
 POW'R-RISER SUB-ASSEMBLY

ITEM CONTROL # DESCRIPTION QTY.

1 88053 Cylinder Assembly 1
2 85464 Support Assembly 1
3 85465 Handle Assembly 1
4 85451 Housing Reservoir 1
5 85457 Handle 2
6 87774 Ring 1
7 86155 Set Screw 3
8 85468 Shaft 2
9 84027 Relief Valve 1
10 85470 Tire & Wheel 2
11 88057* Nipple 1
12 8797301* Over Center Valve 1
13 88060* Hose Assembly 1
14 88068* Hose Assembly 1 USE FIG. 4
15 85473 Pipe Nipple 1
16 86353 Pipe Nipple 1
17 18107* Elbow 1
18 18109* Street Elbow 2
19 93950 Socket Pipe Plug 2
20 5602441 O-Ring 2
21 95306 Roll Pin 2
22 85475 Roll Pin 1
23 93594 Soc. Hd. Cap Screw 4
24 85855 Hex Cap 6
25 93866 Hex. Slotted Nut 2
26 85477 Hex. Jam Nut 2
27 93930 Plate Washer 2
28 93943 Lock Washer 4
29 93782 Cotter Pin 2
30 68000 Breather Vent & Filter 1
31 85853 Nylon Washer 1
32 85455 Base 1
33 86006 Hex. Head Screw 6
34 86007 Washer 30
35 55024 Safety Valve Enclosure Kit 1
36 86225 Eye Bolt 1
37 18117* Swivel Fitting 1
38 84853 Caution Decal 1
39 88066 Spacer 2
40 88059* Elbow 1
41 88058 Nipple 1
42 18970* Elbow 1

* Included in O.C. Valve Kit #18060 that will completely interchange with
older valves.

8
 POW'R-RISER SUB-ASSEMBLY

11 18 38
17 15 9
12 35

42

41
30

10
Fill Plug
19
14 39
40 Torque to
13 37 26 Max. 250 ft.lb.

View A-A 27
25

29
+00
-.01
.03 Gap (Typ)
wheels must have
+.06 free rotation
USE FIG. 4 4.68
-00

(Ref.) (Typ.)
25.5

36
7 23 28
6
2

21

22
20

5 3
18
4
11 10
24.75
17
1
14
12
24
13
20
31
42 41 40
32
41
16 18 37 40 19
33 34 Drain
26.2
Torque to
150 in. lbs.

9
 PUMP & MOTOR MOUNTING ASSEMBLY
#88070

ITEM CONTROL # DESCRIPTION QTY.

1 85501 Motor Air 1
2 66012 Gasket 1
3 88069 Cover Plate 1
4 87831 Gasket-High Pressure 1
5 68090* H.P. Plate Assembly 1
6 84692 S.H.C.S. 4
7 88073 Adapter Valve 1
8 65881 Back Up Washer 2
9 5602012 O-Ring 3
10 66053 Tube High Flow 1
11 66106 Bearing Thrust 1 USE FIG.5A
12 66108 Race Bearing 1
13 68073 Eccentric Assembly 1
14 66473 Race Bearing 1
15 66033 Bearing Thrust 1
16 66474 Race Bearing 1
17 5602010 O-Ring 3
18 68066 Back-Up Washer 3
19 66231* Piston Block Assembly 3
20 5602110 O-Ring 3
21 68192* Low Pressure Plate 1
22 68056 S.H.C.S. 6
23 68084 Gear Pump 1
24 65879 H.H.C.S. 2
25 97485 Lock Washer 2
26 88470 Suction Strainer 1
27 66122 Key 1
28 68064 Tube Assembly 1
29 68057 Seal Plate Assembly 1
30 68058 B.H.C. Screw 4
31 18101 Nipple 1
32 18109 St. Elbow 1
33 18125 Reducer Bushing 1

* For details, see figures 5B, 5C, & 5D.

10
 PUMP & MOTOR MOUNTING ASSEMBLY

C
32
28
33

C Bend tube assembly to 26

insurer proper positioning

View A-A
Position hi-flow cartridge as required to Scale 1/2
assemble lubricator. Lubricator assembly
shown in final location

30
1 Ref.
View C-C

USE FIG. 5A

27

30

29

3 8 2

18 12
Torque to 250 in. lbs.
17

19 6

10
11
20
14 13

15
22
16
Torque to 200 in. lbs.
9
23 21

25

24
Torque to 100 in. lbs. 31

A A

11
 HIGH PRESSURE PLATE ASSEMBLY
#68090

Item Control Descr. Qty.

1 3 4 5 9 10
2
13
8 1 66080 Scr. Adj. 1
12
11 2 68065 Cartridge 1
3 66078 Guide Ball 1
4 66077 Sprg. Hi-Flow 1
5 94414 Ball 1
16 6 5608010 B-U Washer 2
6 7 5602010 O'Ring 1
7
8 66220 Relief Vlv. 1
9 93585 S.H.C.S. 4
6
10 68079 Gasket Wshr. 4
17 11 68081 Ck. Valve 1
Figure 5B 12 68089 Spring 1
18 14 13 92550 Ball 1
14 68083 S.H.C.S. 1
15 68080 Gasket Wshr. 2
16 68087 Pilot Spl. 1
3 5
1 2 4 17 66028 Brg. w/Seal 1
18 68074 H.P. Plate 1
9

PISTON BLOCK ASSEMBLY

10
#66231

Item Control Descr. Qty.

1 66037 Block Piston 1
7 2 90906 Ball 2
3 66042 Spring 1
8
Figure 5C 4 66039 Washer/Copper 1
5 66040 Screw Spring 1
7 66043 Ball Retain. 1
8 66046 Intake-Seat 1
9 66051 Sprg Piston 1
10 66049 Piston 1
2
LOW PRESSURE PLATE ASSEMBLY
1 #68192
3
Item Control Descr. Qty.
1 68047 Low Pres. Plate 1
2 93949 Pipe Plug 5
3 68053 Bushing 1
Figure 5D .157

12
 CYLINDER ASSEMBLY
#88053

5 4 6 2
3 7
8 1 10 9

Tighten Screws to
80 Ft. Lbs. Torque.

7
Dia. Ref.

Figure 6

.18 Ref.

23.42 Ref.

2-Ports (In Line) 16 Relief Valve Port

Ref.

Item Control Descr. Qty.

1 88052 Cyl. Bdy. Weld 1
2 88050 Piston Rod 1
3 88054 Head Gland 1
4 5602251* O'Ring 1
5 5608251* B-U Ring 1
6 93750* Rod Seal 1
7 85371* Piston Seal 1
8 56012079* Rod Wiper 1
9 87793 Steel Plate 1
10 85855 Screw 4

* Items are included in the Packing Kit

#54381.

13
 CONTROL VALVE ASSEMBLY
#88473

Item Control Description Qty.

1 18462 Control Valve 1
2 68310 Manifold (Barksdale Val.) 1
3 93598 S.H.C. Screw 3/8 - 16 x 2 Lg. 4
4 93950 Pipe Plug - Flush Type 2
5 68324 Gasket 1
6 88076 1/4 x 1 1/2 Hex Nipple 1
7 88078 1/4 Female Pipe Swivel Adpt. 1
8 86353 3/8 x 2 Hex Nipple 1
9 88079 3/8 Female Pipe Swivel Adpt. 1

Figure 7

3
Torque to 300 In.
Lbs.

1
1/4 - 18 NPTF
Gage Port
(Retract)
2

4 1/4 - 18 NPTF
Gage Port
(Extend)
6 5

7 8

14
 VALVE
#18462

18 19 20

17 10

16
9
15
8

7
5 A
6
"A" 21 "A"
14 5
22

13
4
12

11 View "A-A"

1
3
2
Figure 7A

INTERCHANGEABLE WITH #85764

ITEM CONTROL # DESCRIPTION QTY.

1 68160 Rotor Assembly 1

2 56020112 O'Ring 4
3 68180 Subplate-Valve. 1
4 5602225 O'Ring 1
5 68026 Thrust Washer 2
6 68155 Thrust Bearing 1
7 5602012 O'Ring 1
8 68035 Upper Valve Blk. 1
9 68024 Detent & Stop Plt. 1
10 93804 Driv-Lok Pin 1
11 5602011 O'Ring 3
12 65882 Back-up Washer 3
13 68181 Shear Seal 3
14 68028 Spring Washer 3
15 68025 Detent Spring 1
16 92549 Ball .250 Dia. 1
17 68032 Washer-Handle 1
18 68157 Flat Grip 1
19 68033 Handle 1
20 68034 Acorn Nut 1/2-20 1
21 98738 Soc. Hd. Capscrew 2
22 5602008 O'Ring 1

15
 HANDLE SUPPORT ASSEMBLY
#85464

Item Control Description Qty.

1 85460 Support 1
2 85494 Pin 1
3 85495 Nut 1
4 85496 Spring 1
5 85497 Retaining Nut 1

Figure 8

1
5

16
 PARTS LIST - AIR MOTOR
#85501

17
15
7 16
1
5 12
14
18

9 13
20
11
19
4
6 3
8
2
10 10

Figure 30

Item Control Description Qty.

1 6028082 Body 1
2 6028083 End Plate, Drive 1
3 6028084 End Plate 1
4 6028085 Rotor Assembly 1
5 6028086* Vane 4
6 6028087* Vane Spring 4
7 6028088* Push Pin 2
8 6028053* Bearing, Drive End 1
9 6028089* Shaft Seal 1
10 6028090* Body Spacer Gasket 2
11 6028091 End Cap, Drive End 1
12 6028092* O'Ring 1
13 6028093 End Cap, Dead 1
14 6028094* End Cap Gasket 1
15 6028096 Muffler Assembly 1
16 6028097 Felt 1
17 6028098 Screen 2
18 6028054 Drive Key 1
19 6028055* Bearing, Dead End 1
20 6028107 Dowel Pin 4
6028099 Repair Kit, Motor
*Items Included in Repair Kit #6028099

17
 FILTER - LUBRICATOR ASSEMBLY
#18233

Air Pressure Inlet

1/2" Steel Pipe Nipple

#88063

Air Fliter
#86241

Bracket
#86454
Fill Plug
Lubricator
#86242 To Motor Inlet Port

Oil Drop
Coupling
Regulator
#88065
1/2" Steel Pipe Nipple
#87320
Elbow
#86243
1/2" Union - #86245
1/2" Steel Pipe Nipple
#88063
Figure 10

Nipple
#88063

Elbow
#88064
Elbow Nipple
#86244 #87316
18
 100 TON
POW'R-RISER

44" MINIMUM
 POW'R-RISER SUB-ASSEMBLY
44 INCH MINIMUM

ITEM CONTROL # DESCRIPTION QTY.

1 88202 Cylinder Assembly 1
2 85464 Support Assembly 1
3 85465 Handle Assembly 1
4 85451 Housing Reservoir (Machined) 1
5 85457 Handle (Machinedº 2
6 87774 Ring 1
7 86155 1/4"-20 x 1/2 Set Screw 3
8 85468 Shaft 2
9 84027 Relief Valve (10,000 lbs.) 1
10 85470 16 x 4 Semi-Pneu. Tire & Wheel 2
11 88057 5" Lg. Nipple 1
12 8797301 Over Center Valve 1
13 88060 1/4" x 17" Hose Assembly/Spg. 1
14 88068 3/8" x 19" Hose Assembly/Spg. 1
15 85473 3/8" x 1/4" Pipe Nipple 1
16 86353 3/8" x 2" Lg. Pipe Nipple 1
17 18107 3/8" x 90 Elbow 1
18 18109 3/8" x 90 Street Elbow 2
19 93950 1/4" Socket Pipe Plug 2
20 5602441 7-1/2" x 7" x 1/4" O-Ring 2
21 95306 3/8" x 2" Lg. Roll Pin 2
22 85475 1/2" x 2.5" Lg. Roll Pin 1
23 93594 3/8"-16 x 1" Lg. Soc. Hd. Cap Screw 4
24 85855 5/8"-11 x 1-1/2" Lg. Ft. Hd. Hex Cap 6
25 93866 3/4"-10 Hex. Slotted Nut 2
26 85477 1-1/8"-12 Hex. Jam Nut 2
27 93930 3/4" Plate Washer 2
28 93943 3/8" Lock Washer 4
29 93782 1/8" x 1-1/4" Cotter Pin 2
30 68000 Breather Vent & Filter 1
31
32 88204 Base 1
33 86006 7/16"-14 x 1-1/2" Lg. Hex. Hd. Screw 6
34 93944 7/16" Washer 6
35 55024 Safety Valve Enclosure Kit 1
36 86225 3/8" Threaded Eye Bolt 1
37 18117 3/8" Swivel Fitting 1
38 84853 Caution Decal 1
39 88066 Spacer (1/4 Thick) 2
40 88059 1/4" x 90 Elbow 1
41 88058 1/4" x 3-1/2" Lg. Nipple 1
42 18970 1/4" x 90 St. Elbow 1

USE FIG. 11

19
 POW'R-RISER SUB-ASSEMBLY
44 INCH MINIMUM

USE FIG. 11

43

36
23 28
6 7
2

22
21

3
20
43.17 18
5

4 10

11
17
1
14
12

32 24
20 13
1.25
42
41 41
19
34 16 18 40
33 40 DRAW
37
Torque to .150 In. lbs.
28

NOTE: For part numbers no shown in Fig. 11-12 (44" Min.), refer
to standard Pow'r-Riser Fig. 1-5D and 7-10.

20
 CYLINDER ASSEMBLY 44 INCH MINIMUM
#88202

3 5
4 6
8 7 10 9
2 1

Tighten Screws
to 80 Ft. lbs.
Torque.
7
DIA. REF.

.18 REF

41.87 REF.

NOTE: Items with * are included in the packing kit #54381 Figure 12

2-Ports (In Line) 16 Relief Valve Port

REF.

Item Control Descr. Qty.

1 88201 Cyl. Bdy. Weld 1
2 88050 Piston Rod 1
3 88054 Head Gland 1
4 5602251* O'Ring 1
5 5608251* B-U Ring 1
6 93750* Rod Seal 1
7 85371* Piston Seal 1
8 56012079* Rod Wiper 1
9 88203 Steel Plate 1
10 85855 Screw 4
21
 MAINTENANCE INSTRUCTIONS

A. OIL

1. The "full level" of the reservoir is approximately 5 gallons. Fill within 2" from the top
of reservoir as needed. Check regularly.

2. 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 50 hours of operation or every 90 days,
whichever occurs first.

3. 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 8 hours, as water accumul-
ates in the bottom of the reservoir. Tilt the jack back and when the drain plug (#19,
fig. 4) 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 conden-
sation 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)

1. Clean Oil Filter Screen Periodically.

a. Loosen and remove reservoir plate bolts and retract tube assembly (#10, fig. 3).
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.

22
 MAINTENANCE INSTRUCTIONS (CON'T)

B. PUMP ASSEMBLY (Con't)

2. 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. 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 #9 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 .0015". The total end clearance (between the sides of the rotor and the
end plates) is .002". The vanes take up their own wear and will last 5,000-12,000
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 oper-
ating pressures above 100 PSI (6.89 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 3/4 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 instal-
lation of an automatic air line oiler set to feed 1-3 drops per minute. Use Simplex
#18243 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.
23
 MAINTENANCE INSTRUCTIONS

PARTS ARE DESIGNATED WITHIN PARENTHESES BY FIGURE NO. & ITEM NO.,
i.e., (4-17) indicates (Figure 4 - item 17)

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 (3-9) 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, #93950 (4-19).

b. Disconnect tube assembly, #88067 (3-10).
c. Remove (14) mtg. screws, #93582 (3-13).
d. Lift the left side of pump mtg. assembly, disconnect hose assemblies #85471 (4-13)
and #85472 (4-14), from the bottom of pump mounting assembly.
e. Carefully remove pump mtg. assembly.

Cylinder Piston Removal (Seal Replacement) (Refer to Figures 3 & 6)

a. Remove load cap, #18333 (3-10).

b. Raise the piston almost all the way up.
c. Remove head gland nut, #88054 (6-3). Take piston rod, #88050 (6-2) out from the
cylinder.

Cylinder Body Removal (Refer to Figures 4 & 6)

a. Follow pump removal steps (a-e) above.

b. Remove hoses, #85471 (4-13) and #85472 (4-14).
c. Remove overcenter valve assembly (Fig. 4, View A-A)
d. Remove pipe nipple, #86353 (4-16) along with elbow #18109 (4-18)
e. Remove pipe nipple, #85473 (4-15) and relief valve, #84027 (4-9)
f. Remove (6) aluminum base mtg. screws, #86006 (4-33) and (30) washers #86007
(4-34).
g. Take off nylon washer, #85853 (4-31); remove (6) mtg. screws, #85855 (4-24).
h. Remove ring, #87774 (4-6).
i. Remove steel plate mtg. screws, #85855 (6-10).
j. Pull off reservoir, #85541 (4-34), from cylinder.
k. Remove gland nut, #88050 (6-3).
l. Take out piston rod, #88054 (6-2).
m. Replace seals as required.
n. Reassemble in reverse order. (See following notes.)

Care must be taken to reassemble (39) washer #86077 (4-34) in the same pattern as
shown in Figure 4.
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 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 Cause -- Solution

Sporadic Cylinder Action 1. Air in the hydraulic system. Cycle the jack
several times under no load.
2. Check reservoir oil level.

Noisy Operation 1. Air in system. (Same as Above)

2. Be sure the oil reservoir is filled to normal
level.
3. Check all points where air might leak into
system.

Pump Oil is Overheating 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.
4. See #1 of page 3.

Pump runs by will not pump oil, or piston
rod moves by will not lift load.
1. Pump is not primed. Run pump a few
minutes, tipping jack back and forth.
2. Check internal relief valve.
3. Flush filter screen.
4. Defective control valve. (Troubleshoot
separately or replace valve).
5. Replace o-ring (6 & 7, Fig. 5B)
6. Damaged o-rings. Take to nearest
Simplex service center for repair.

Piston extends by will not retract.
1. Pump not developing enough pressure.
(2,500 PSI required for retraction)
a. Check for internal pressure leaks.
b. Adjust internal relief. (#8, Fig. 5B)
c. Replace o-rings. (#6 & 7, Fig. 5B)
2. Defective O.C. Valve (#12, Fig. 4)
Replace.

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