Simplex GA9 Series Manuals

GA9 Series Reference # - TD080 Rev. - C Date - 0411 2525 GARDNER ROAD, BROADVIEW, IL 60155 1.800.323.9114 • Outside U.S. 1.708.865.1500 www.tksimplex.com - Note - This Operational Manual is intended as a technical guideline only. SIMPLEX accepts no liability for any use or reliance made of any information in this Operational Manual. All information, illustrations and specifications in this Operational Manual are based on the latest information available at the time of publication. SIMPLEX reserves the right 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. ©2011 SIMPLEX IMPORTANT - READ CAREFULLY This manual contains important information about 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 lubrication, 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. 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. CONTENTS SECTION Receiving Instructions ...............................................................................................................................................1.0 Safety ........................................................................................................................................................................2.0 Technical Specifications ............................................................................................................................................3.0 Basic Operation and Function ...................................................................................................................................4.0 Basic Operation .........................................................................................................................................................4.1 After Completing the Job ...........................................................................................................................................4.2 Periodic Maintenance ................................................................................................................................................5.0 Maintain Oil Level ......................................................................................................................................................5.1 Troubleshooting .........................................................................................................................................................6.0 ••• 2 ••• 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 all 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 SIMPLEX Distributor for clarification. 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: 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. Gauges help the user see what is happening with the hydraulic pressure in the system. WARNING: 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 flames and heat. Excessive heat will soften seals, resulting in fluid 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. WARNING: 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. Untreated oil injection could be fatal, but normally just causes severe injury. 3.0 TECHNICAL SPECIFICATIONS Model Tool Type Control Usable Oil Capacity (cu. in.) Oil Flow @ 0 psi (cu. in.) Oil Flow @ 10,000 psi (cu. in.) Operating Air Pressure Range (psi) Weight (lbs) GA90 S/A Foot Pedal 90 68 11 60 - 150 18.5 GA9230 S/A Foot Pedal 230 68 11 60 - 150 32.6 GA9460 S/A Foot Pedal 460 68 11 60 - 150 41 GA90-R S/A Pendant 90 68 8 60 - 150 23.5 GA9230R S/A Pendant 230 68 8 60 - 150 37.6 GA9230D D/A Control Valve 230 68 11 60 - 150 31.6 GA9460D D/A Control Valve 460 68 11 60 - 150 41 DOCUMENTED FLOWS WERE TESTED AT 110 PSI, 10 CFM. GA9 Series Foot Pumps www.tksimplex.com ••• 3 ••• 4.0 BASIC OPERTION AND FUNCTION 1. Locate and remove the shipping plug and discard. Ensure the oil level is just below (approx. 1/2”) the oil filler plug hole.Install the vent / oil fill / dip stick plug. 2. Remove air inlet shipping plug and discard. Pour a teaspoon of good quality, air tool #10 wt. non-detergent oil into the air inlet port). Install the appropriate air supply coupler and a 3/8” NPT hydraulic connection. The air quick disconnect configuration of your choice can be installed in the threaded hole underneath the foot pedal labeled “PUMP”. An in-line filter/ regulator/lubricator should be installed close to pump. Add a few drops of SAE 10 oil to the air intake weekly if no lubricator is used or when pump will be idle for a long time. 3. Remove the pressure port shipping plug and discard. Use at least 1-1/2 wraps of Teflon tape (or suitable sealant) on the hose fitting threads. Make sure the first complete thread is free from tape or sealant so they do not enter and contaminate the hydraulic system. Thread the hose fit ting into the pump manifold’s threaded hole and turn until snug - make sure the hose fitting threads are not cross-threaded. 4.1 OPERATION 1. Make sure the pump is on a level surface. 2. Connect Foot Pump to an external air source that is capable of supplying 90 PSI @ 10 CFM. Next connect a 3/8” NPT quick disconnect coupler or hose to the oil outlet side. (SIMPLEX recommends that a gauge adaptor and 10,000 PSI gauge be use during operation). Connect tooling (I.e. cylinder, bender, or cutter) 3. Check for leaks in system and repair as needed. Before repairs are made, disconnect air source and application, then depressurize reservoir. Do so simply by pressing the pedal or pendant button for three seconds (see figure 1). 4. To build pressure, depress the pedal or pendant button where “PUMP” is located. Operate pump until desired position is reached and/orpressure is obtained (see figure 1). 5. To retract application, simply press down on the RELEASE valve or pendant button portion of the pump. Fully depressing pedal will LOCK the DETENT feature to “on” (see figure 1). 4.2 AFTER COMPLETING THE JOB Before disconnecting hoses, fittings, etc., be sure the ram is unloaded and retracted, then disconnect air source and hydraulic connections. Store the pump in a clean, dry area. 5.0 PERIODIC MAINTENANCE A) MAINTENANCE 1. Inspect hose and connections daily. Replace damaged components immediately with Simplex Authorized replacement parts only. 2. Tighten connections as needed. Use pipe thread Teflon when servicing connections. NOTE: DO NOT OVER TIGHTEN CONNECTIONS. 3. When Not In Use Or During Storage: • Disconnect pump from air source, depressurize and disconnect hydraulic hoses from application. • Wipe clean, throughout. • Shelter the pump with protective cover. • Store in clean, dry environment. • Avoid temperature extremes. B) HOW TO FILL THE RESERVOIR 1. Disconnect hydraulic hose from application, remove air source from pump. 2. With reservoir horizontal, remove the vent / oil filler plug. 3. Use a small funnel to fill reservoir so the oil level remains the distance stated below in the table, distances are measures from the top of the fill hole. Models Recommended Oil Level Range from the Top of Fill Hole Minimum distance Maximum distance GA90, GA90R 1.25” .50” GA9230, GA9230D, GA9230D 3.5” 1.5” GA9460, GA9460D 1.75” 1.5” continued on next page. Figure 1 OIL AIR SPACE MINIMUM FILL LEVEL MAXIMUM FILL LEVEL MEASURE FROM TOP OF FILL HOLE CUTAWAY