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All maintenance, assembly and operating advice prescribed in the-
se Operating Instructions must be observed in order to ensure
complete functioning and safety.
The pumps are not designed for lengthy dry runs (without pum-
ping medium). A lengthy dry run would result in a separation of
the lubricating film in the high-pressure part. A short dry run (e.g.
during venting) is harmless.
4.2 Emissions
Expanding compressed air causes a certain noise level, depending
on the specific application. Air exhausting from the silencer may
be fouled by water and oil (grease). It is also possible for small ice
crystals to form at the silencer which may come off and fly around.
Hence, all persons have to wear protective glasses and, if need be,
ear protection in the vicinity of running pumps.
4.3 Safety hazards
During pump operation both the drive part and the high-pressure
part are under pressure. Hence, it has to be borne in mind that
any gases or liquids emerging due to a defect or during normal
operation are also under high pressure and must not be collected
or diverted by objects or body parts. Rather, it has to be seen to it
that any defective pump is immediately depressurised and repai-
red.
Maintenance and repair work may only be performed at depressu-
rised units.
4.4 Safety at place of installation
MAXIMATOR pumps must not be operated in closed containers
because the escaping drive air may burst the container.
Die hydraulic bolted connections at intake and pressure fittings
must not be unscrewed, even if such facilitates installation of a
unit. All bolted connections must have tight seats in order to avo-
id leakages and damage.
The pumps have to be installed in such a manner that their opera-
ting elements and bolted connections are freely accessible at any
time.
5 Installation
5.1 Assembly
The installation position of the pumps can be optionally chosen.
However, a vertical position has certain advantages for sealing
durability because gravity will not have to be absorbed by the sea-
lings. Angle brackets are available to fasten the pumps. In case
that a pump is only fastened at its intake and pressure fittings it
has to be seen to that the connections used are fir to withstand
the pulsating loads of the pump.
It is essential to avoid any foreign matter from getting into the
pump connections during assembly (e.g. drilling dust during wall
mounting). This is why the blind plugs at the pump connections
should only be removed shortly before fastening the respective
connections.
5.2 Compressed-air system
It is recommended to use for the compressed air connection one
of our air control units, consisting of filter, water separator, shu-
toff valve, pressure controller, pressure gauge and, if need be,
safety valve. In case that there is no maintenance unit used the
quality of compressed air has to be ensured according to our
requirements.
5.2.1 Compressed-air quality
1 Solid matter:
Maximum particle size: 5 µm
Maximum particle concentration: 5 mg/m
1 Dew point:
5.2.2 Compressed-air oiler
Normally, a compressed-air oiler is not necessary. All moving pump
parts are treated with a special grease during assembly.
The grease may gum when the pump is operated with extremely
dry air over a longer period. In such case it is recommendable to
use a compressed-air oiler.
Caution! After a compressed-air oiler is used once the respective
pump must not be operated without an oiler since it purges the
entire grease from the pump and thus there is no continuous lubri-
cation any longer. Re-lubrication with a MAXIMATOR grease will
put things right.
Upon use of a compressed-air oiler the oil content of the air
should be 1-5 mg/m
5.2.3 Piping cross-sections
The air connection should not be smaller than the connection thre-
ad, reduction to a smaller connection thread may result in pump
power loss and malfunction. Overlong supply pipes may cause
problems due to pressure drop in small pipes.
5.2.4 Direct pilot valve air
When the pump is designed for operation with direct pilot valve
air it should be connected upstream from a pressure controller.
Thus, the pump will have a better reversing behaviour. If direct
pilot valve air is not connected the pump will not work. (Direct
pilot valve air is available as a special option in M and S pumps
and is a standard feature in S...D and G pumps. The connection is
marked with „x").
5.3 Hydraulic system
The admissible pressures and cross-sections of all used hydraulic
pipes and accessories have to be matched to the pump. Otherwise
the pump efficiency and safety could be impaired.
5.3.1 Suction pipe
The suction pipe must be low-pressure-tight in order to obtain an
optimum pump efficiency. Cutting-ring screw fittings are not sui-
ted. Suction pipes must not be specified larger or smaller than the
pump suction connection. When the above rules are observed the
following suction heads are attained:
Pump type
M4 – M12, S15 – S35, G10 – G35
M22 – M72, S60 – S150, G60 – G150
M111 – M189, G250 – G500
Admission pressure in the suction pipe will not cause any pro-
blems but facilitates higher suction heads and smaller suction pipe
cross-sections.
A filter with a mesh width < 100µm should be fitted in the suction
pipe in order to prevent damage at the suction and pressure val-
ves as well as the HP sealing.
5.3.2 Pressure pipe
The pressure pipe and the pertaining accessory parts will have to
withstand the maximum pump outlet pressure. This pressure resi-
stance may only be fallen short of when a suitable safety valve is
installed in the pressure pipe. The cross-section of the pressure
pipe should not be smaller than that of the pressure connection. A
smaller cross-section will result in a reduced pumping capacity
3
and a higher heating of the pumping medium.
E419-2
+ 10°C = water content 9.4g/m
up to +2°C = water content 5.6g/m
3
.
Max. suction head
2.0 m
1.0 m
0.5 m
3
3
7
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