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MAXIMATOR Hydraulic Units - General Informations



MAXIMATOR Hydraulic Units - General Informations

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General information:

MAXIMATOR power packs for oil, water or aggressive media are complete hydraulic units ready for connection which are provided for generating operating pressures up to 7,000 bar. The hydraulic systems can be used for all kinds of testing and clamping or for other functions requiring a determined pressure.

The pressure will be generated by means of a pneumatically operated MAXIMATOR pump. The pump will be connected to the existing industrial compressed-air ductwork system. For generating the pressure, an electric connection will not be necessary.

MAXIMATOR power packs can be equipped with all MAXIMATOR pumps. Restrictions result only from determined structural dimensions as well as from the flow rates of the pumps being necessary for the respective function.

For the simple commissioning and unproblematic application, MAXIMATOR power packs will be equipped with all required components. Part of them is an air control unit with combined filter and water seperator, a pressure-regulating valve, a pressure control gauge as well as a manual shut-off valve for stopping off the drive air pressure.

For all applications within the range of the oil hydraulic, the pumps will be mounted in the oil tank in a compact and space saving manner. In case of operation with water or with aggressive media, the pump will be mounted on the tank. According to standard, there can be selected among tank capacities from 6.5 l to 70 l. Larger-sized tanks are available on demand.

On request, the tanks can be provided with carrying handles or on wheels (to be recommended for all G-type pumps as well as for tank capacities from 30 l).

On the high-pressure side, the power pack will be equipped with a pressure relief valve (expansion valve) as well as with a manifold block with one or several pressure outlets for connecting the test pieces (which can be shut off separately or completely on request).

For indicating and monitoring the operating pressure, liquid-damped pressure gauges of the accuracy class 1.0 or 1.6 (higher accuracies are possible on demand) can be delivered in different sizes for pressures up to 7,000 bar.

With the above specified scope of supply, the MAXIMATOR power pack is ready for connection. For operating the hydraulic unit, only the drive air piping has to be connected and the tank has to be filled with the provided operating liquid.

MAXIMATOR offers an extensive volume of accessories for all cases of application. Part of them are pressure switches, float valves and pneumatically or electrically operated directional valves for actuating cylinders. Connecting adaptors, quick couplings, pressure filters, high-pressure hoses as well as shut-off valves and control valves are available too.

We design the MAXIMATOR power packs according to your requirements. Our sales engineers in the engineering departments as well as our co-workers in the Works Zorge are pleased to give you expert advice and will recommend you the respective power pack being suitable for your special case of application.

Functional description:

Components in Modular Design:

Pump model:

  • MO, S for oil service up to maximum 1,000 bar;
  • M, G for oil and water service up to maximum 7,000 bar;
  • MSF, GSF for special liquids to maximum 1,450 bar

Air control unit:

comprising combined filter pressure regulator, control pressure gauge and shut-off valve

  • C1 for M series
  • C1.5 for S series
  • C2 for G series

Air safety valve:
SV mounted in the air line

Tank sizes:

  • 6.5 liter
  • 13 liter
  • 30 liter
  • 70 liter

Standard of aluminium, stainless steel on request.

Note: MAXIMATOR pumps MO and S series are integrated in the tank.

All other pump series will be mounted on top of the tank.

Mobility of the packaged pump system:

  • F moveable
  • T portable
  • K jack ring

Relief valve:

EV with return line to the tank

Pressure gauge:

Pressure range / Diameter of the housing (cl. 1.6/1.0/0.6, glycerine damped)

Operating liquid:

  • O Oil (tank of aluminium, components galvanized)
  • W Water (tank of aluminium, components of SS)
  • VA Stainless steel (tank of 1.4571 or 1.4305)

Manifold block with pressure outlet(s):

A1 - 1 pressure outlet to
A6 - 6 pressure outlets, depending on tank size
V Option: Shut-off valve for pressure outlet (AV1-AV6)

Hand lever:

H only available for M22 to M189, single acting, single stage

Other options:

  • SCHW Float valve for automatic filling of the tank, i. e. from the water line
  • SCHL HP hose, model SK
  • ZR Additional return connection

Specials on request

Coding example:

M 189-01 / C1 / SV / 13 / F / EV / 0-1600 (160) / W / A2 / H / SCHL

Power pack with pump type M189-01 with hand lever, air control unit C1, air safety valve, aluminium tank, volume 13 liter, on wheels, manually relief valve EV, pressure gauge 0-1,600 bar, Ø 160 mm, suitable for water service, manifold block with two pressure outlets, 2 pces. hoses.

Application and implementation:

The movable and portable MAXIMATOR hydraulic power packs can be used wherever hydraulic pressures are required. They are to be found for example in the steel construction, boiler construction, tank construction and reactor construction as well as in yards, smelting plants, machine factories and locksmith's shops. For years they have proved themselves in inspection and acceptance processes as well as in the hydraulic working and clamping systems.

The power packs are also provided for actuating hydraulic punches and punch systems. Among others they will be used in aircraft yards for lifting aircrafts, for clamping large-sized devices, for checking pressure vessels and pressure systems.

In the tool hydraulic, MAXIMATOR units will be used for pressure oil junctions as well for mounting and pulling-off large-sized toothed gears.

Furthermore, the systems will be used in hydraulic presses, among others also when high pressure must be maintained for a long time, such as in case of tire and vulcanizing presses as well as for presses overload protections. For such purposes, the hydraulic unit can be delivered with reversing devices permitting an one-sided or also twosided admission to the press. Direct admission of compressed air to the return side enables a connection for the quick return. The hydraulic units have also proved to be an outstanding solution for isostatic pressing procedures.

For realizing regular pressure tests (TÜV) at pressure vessels, MAXIMATOR offers the complete solution with regard to the pressure generation. These power packs will always be set up upon customer's request.

The required hydraulic pressure will be generated by means of air-lift pump. In this connection, the hydraulic pressure corresponds to the set air pressure multiplied by the transmission ratio of the pump. When the appliance reaches the pre-set pressure, it stops automatically and maintains the pressure until arising a pressure drop caused through leakage or the like. The appliance starts automatically and functions again until having reached the pre-set pressure.

All the controlling and regulating processes are of unsurpassed simplicity because of the compressed-air drive. So, the complete appliance is very robust, operationally reliable and insensitive to hardest operating stresses. The power pack will not be damaged through moist rooms, dust or higher temperatures. The MAXIMATOR hydraulic units are explosion-proof because no electric energy is required.

Advantages of the MAXIMATOR power packs:

  • Standstill of the pump when reaching the set final pressure
  • No energy consumption in case of long pressure holding times
  • No dissipated heat during the pressure holding phase
  • Substitute of leakages by automatic re-delivery through the pump
  • Control of the operating pressure through simple adjustment of the aire drive pressure
  • Simple installation, operationally reliable, easy to maintain

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