SIMPLEX 86183 Hydraulic Cylinders Instruction Manual
- June 9, 2024
- Simplex
Table of Contents
SIMPLEX 86183 Hydraulic Cylinders
IMPORTANT RECEIVING INSTRUCTIONS
Visually inspect all components for shipping damage. Shipping damage is not
covered by warranty. If shipping damage is found, notify carrier at once. The
carrier is responsible for all repair and replacement costs resulting from
damage in shipment.
SAFETY FIRST
SAFETY PRECAUTIONS
Read all instructions, warnings, and cautions carefully. Follow all safety precautions to avoid personal injury or property damage during system operation. Simplex cannot be responsible for damage or injury resulting from unsafe product use, lack of maintenance, or incorrect product and/or system operation.
Failure to comply with the following cautions and warnings could cause equipment damage and 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 indicates a potential danger that requires correct procedures or practices to avoid personal injury.
- DANGER is only used when your action or lack of action may cause serious injury or even death.
- 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, 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.
- DANGER: To avoid personal injury keep hands and feet away from the cylinder and workpiece 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 max. the pressure of 10,000 psi [700 bar]. 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 the 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 the 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 hoses 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 packings and seals, resulting in fluid leaks. Heat also weakens hose materials and packing. For optimum performance do not expose equipment to temperatures of 65°C [150°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.
- WARNING: Only use hydraulic cylinders in a coupled system. Never use a cylinder with unconnected couplers. If the cylinder becomes extremely overloaded, components can fail catastrophically causing severe personal injury.
- WARNING: BE SURE THE SETUP IS STABLE BEFORE LIFTING THE LOAD. Cylinders should be placed on a flat surface that can support the load. Where applicable, use a cylinder base for added stability. Do not weld or otherwise modify the cylinder to attach a base or other support.
- Avoid situations where loads are not directly centered on the cylinder plunger. Off-center loads produce considerable strain on cylinders and plungers. In addition, the load may slip or fall, causing potentially dangerous results.
- Distribute the load evenly across the entire saddle surface. Always use a saddle to protect the plunger.
INSTALLATION
-
Make hydraulic connections. For single-acting cylinders (1) use a pump with a release valve (or a 3-way valve) and one hose. For double-acting cylinders (2) use a pump with a 4-way valve and two hoses.
WARNING: On double-acting cylinders be certain that hoses are connected at BOTH couplers. Never attempt to pressurize a double-acting cylinder if only one hose is connected. -
Fully hand-tighten all couplers. Loose coupler connections will block the flow of oil between the pump and the cylinder.
-
Remove air from the cylinder:
Single-acting cylinders: Position the cylinder so that the plunger is pointed down and the cylinder is lower than the pump. Fully extend and retract the cylinder several times, until the operation is smooth. Double-acting cylinders: Lay the cylinder on its side so that the couplers are facing up. Fully extend and retract the cylinder several times, until the operation is smooth. -
Install adaptors and attachments as required.
NOTES:
- During adaptor installation, extend the plunger and apply approximately 1500 to 2000 psi [103 to 138 bar] of hydraulic pressure. This will help keep the plunger from turning inside the cylinder base.
- Do not allow the plunger to rotate during adaptor installation. Plunger rotation may damage the internal seals and/or the plunger return spring (if equipped).
- Hand-tighten adapters and attachments until full thread engagement occurs and the item can no longer be turned by hand. Do not use tools.
- Always check for the full thread engagement. Thread damage may occur if the cylinder is loaded and threads are not fully engaged.
- Note that the plunger threads on single-acting cylinders are not rated for the full cylinder load. Forces must be transferred directly from the adapter or attachment to the face of the plunger, and not through the threads. For this reason, it is very important to verify that the adapter or attachment is fully installed on the plunger.
- Use care when installing adaptors and attachments. Be careful not to nick or mar the plunger rod surface.
- Collar threads are rated for the full capacity of the cylinder when fully engaged in attachments.
- WARNING: Some cylinder attachments require that the cylinder be used at no more than 50% of its rated capacity. Refer to the accessory instruction sheet for additional information.
OPERATION
Operate the hydraulic pump to advance and retract the cylinder. Some single-
acting cylinders are spring-return, and others are load-return. The speed of
retraction is affected by the length of the hose and other restrictions in the
line. Double-acting cylinders are powered in both directions by the pump.
The cylinder stop ring is designed to take the full load. However, to reduce
cylinder wear, use less than full stroke and pressure when possible.
RELIEVING TRAPPED PRESSURE
Pressure can sometimes become trapped in a hydraulic cylinder if a hose is
disconnected before pressure is completely relieved.
If a trapped pressure condition occurs, always use the Simplex model CT-604
coupler bleed tool (available from your Authorized Simplex Distributor) to
safely relieve the remaining pressure.
- DANGER: Never attempt to relieve hydraulic pressure by loosening a coupler. Trapped hydraulic pressure can cause a loosened coupler to dislodge unexpectedly with great force. Serious personal injury or death will result if the coupler becomes a projectile and strikes persons working in the area.
- WARNING: Loosening a coupler may result in an escape of high-pressure oil that can penetrate the skin. Serious personal injury or death could result.
- WARNING: Never use a hammer and punch (or another similar method) to unseat a coupler check ball that is under pressure. Serious personal injury or death could result due to the sudden and uncontrolled escape of high-pressure oil.
MAINTENANCE
- Use only Simplex oil with the cylinder. The use of any other oil may invalidate your warranty.
- Use dust cap(s) when the cylinder is disconnected from the hose(s). Keep the entire cylinder clean to prolong its life.
- Store cylinders upright to prevent seal distortion.
- Single-acting cylinders only: Before long-term storage, fully extend and retract the plunger once. Then, store the cylinder upside-down. This will help protect the cylinder from corrosion and seal distortion.
TROUBLESHOOTING
Refer to the troubleshooting chart for a list of typical cylinder problems and possible causes. The troubleshooting chart is not all-inclusive and should be considered only as an aid to help diagnose the most common problems.
The cylinder should be repaired only by trained and experienced hydraulic technicians.
- WARNING: Single-acting cylinders are spring-loaded and require special disassembly techniques to prevent personal injury.
TROUBLESHOOTING CHART
TROUBLESHOOTING CHART
PROBLEM| POSSIBLE CAUSE
The cylinder will not advance.| The pump release valve is open.
Coupler is not fully tightened.
The oil level in the pump is low.
Pump malfunctioning.
The load is too heavy for the cylinder.
The cylinder seals leaking.
The cylinder advances part way.| The oil level in the pump is low.
Coupler is not fully tightened.
Cylinder plunger binding.
Cylinder advances in spurts.| Air in the hydraulic system.
Cylinder plunger binding.
The cylinder advances slower than normal.| Leaking connection.
Coupler is not fully tightened.
Pump malfunctioning.
The cylinder advances but will not hold.| Pump malfunctioning.
Leaking connection.
Incorrect system set-up.
The cylinder seals leaking.
The cylinder leaks oil.| Worn or damaged seals.
Internal cylinder damage.
Loose connection.
The cylinder will not retract or retracts slower than normal.| The pump
release valve is closed.
Coupler is not fully tightened.
The pump reservoir is overfilled.
Narrow hose restricting flow.
Broken or weak retraction spring (if equipped).
The cylinder is damaged internally.
Oil leaking from the external relief valve.| Coupler not fully tightened
Restriction in the return line.
References
Read User Manual Online (PDF format)
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