Installation and Maintenance Manual
MAXIMATOR
SERIES
PUMPS
Model #
Serial #
Order #
Mfg. Date
When ordering spare parts please specify model, serial and order numbers.
INTRODUCTION
The Maximator pump described in this manual is a pneumatically operated, gate valve controlled
piston pump similar in style to a double-acting pneumatic cylinder.
The pump model number indicates the ratio of areas between the pneumatic piston and the
hydraulic plunger. For example, the S60 pump has an area ratio of 60:1 between the pneumatic
piston and hydraulic plunger.
This relates to a maximum hydraulic output pressure that is 60 times greater than the pneumatic
drive pressure. e.g. With 100psi air, the outlet would be 6,000psi.
INSTALLATION
The pump can, in principle, be installed in any position but maximum service life of the seals is
achieved in a vertical installation.
There are two 3/8"-16 taps in bottom of body for use in mounting the pump.
Printed in USA Page 1
COMPRESSED AIR SUPPLY
Do not use an air lubricator because the pump was lubricated with a silicon free grease when
built. (Kluber Lube)
A compressed air filter is required and if the air is not dry, a water separator must be used.
Air control packages including a filter, regulator, gauge and shut-off valve are available as an
option.
The air pressure connection is a 1/2" FNPT and is located at the spool valve housing.
HYDRAULIC SECTION
Attention! Never loosen the cap nut in the hydraulic seal area of the pump to orient the pump
for installation. This nut must always be tight to assure proper operation of the high pressure
seals.
The suction and discharge piping must be at least the same size or larger, as the pump
connections and properly rated for the pump being used.
A suction filter with a maximum of 100 mesh should be installed in the suction line.
The discharge and suction connections are in the sides of the pump head.
INITIAL SET-UP
The liquid pressure can be precisely selected by adjusting the air pressure according to the
pressure ratio of the pump being used.
The pump will stop and maintain pressure for an indefinite period of time, at about 100% to
110% of the ratio, assuming no air or hydraulic leaks.
For example, an S60 pump with an air drive pressure of 100psi, will operate at a pressure of
6,000psi and completely stop at about 6,600psi.
Operate the pump slowly until it is completely primed.
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MAINTENANCE
USE ONLY ORIGINAL MAXIMATOR SPARE PARTS
The air drives of all liquid pumps are factory pre-treated with silicon free grease (Kluber Lube)
and require no further lubrication except during routine maintenance.
Pumps can be repaired at your local authorized service center or returned directly to
your distributor for quick turn-around service.
Pumps returned for repair should be accompanied with the pump s model, serial and order
numbers as well as mfg. date and description of the problem / symptom.
DESCRIPTION OF OPERATION
The automatically operated pump is controlled by a floating slide valve which alternately applies
air pressure to the piston and subsequently vents the air again. The control system as such is
operated with out springs and arresting fixtures as pressure is alternately supplied to and vented
from the front surfaces of the pneumatically operated floating slide valve.
The main parts in the hydraulic section are the pump body, plunger, seals with thrust rings and
inlet and outlet check valves. The check valves are rated for full flow with dynamic sealing.
TROUBLESHOOTING - PNEUMATIC SECTION
Symptom: Pump cannot be operated at low air pressure.
Cause: Excessive friction of O-rings on spool valve
Remedy: Relubricate or replace the O-rings
Symptom: Pump can only be actuated at high air pressure.
Cause: Air escapes through the piston guide in the top air cap.
Remedy: Replace O-ring on the piston extension.
Symptom: Pump runs slowly or not at all.
Cause: Exhaust or spool valve is icy.
Remedy: Stop pump for a short while and, if necessary, clear air line and supply of moisture.
Symptom: Pump will not run and air escapes through the exhaust muffler.
Cause: Pilot valve tappet is not sealing in top cap.
Remedy: Clean and grease tappet, check for wear and replace if necessary.
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Symptom: Pump will not run and air escapes through small holes in the spool valve housing.
Cause: Spool valve fails.
Remedy: Clean spool valve and sleeve, check O-rings and sleeve, lubricate and/or replace.
Symptom: Pump will not run and escapes through the small holes in the bottom cap.
Cause: Pilot valve tappet is not sealing in the bottom cap.
Remedy: Clean and grease tappet, check for wear and re[lace if necessary.
Symptom: Pump operates at a high frequency and short strokes.
Cause: Pilot valve defective.
Remedy: Clean, check and lubricate pilot valve parts or replace if necessary.
TROUBLESHOOTING - HYDRAULIC SECTION
Symptom: Pump does not have flow, operates irregularly or does not maintain pressure.
Cause: 1. Air in the hydralulic system.
2. Suction line of excess length.
3. Suction pipe size to small.
4. Failure of one of the chack valves.
5. Suction filter is blocked.
6. High pressure seal is worn excessively.
Remedy: 1.1 Check suction line and pipe joints for leaks.
1.2 Check seals between air and high pressure sections.
2. Shorten line as much as possible.
3. Increase suction pipe size.
4. Check both valve assemblies and clean or replace if necessary.
5. Clean suction filter
6. Replace seal.
Symptom: Fluid escapes through the air exhaust.
Cause. Worn high pressure seal.
Remedy: Clean fluid from air section, relubricate and replace seal.
SERVICE
For factory authorized service, contact your local Distributor.
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