AME 15000 User manual

Instruction Sheet
15000, 15020, 15040
AIR HYDRAULIC PUMP
1.0 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.
Warranty of this unit will be void on any part if the unit subjected
to misuse due to overloading, abuse, lack of maintenance and
unauthorized modifications. No warranty – verbal, written or
implied – other than the official, published AME new machinery
and equipment warranty will be valid with this unit. In addition, it
is your responsibility to be aware of existing Federal, State and
Local codes and regulations governing the safe use and
maintenance of this unit.
SAFETY FIRST
2.0 SAFETY ISSUES
Read all instructions, warnings and cautions
carefully. Follow all safety precautions to avoid
personal injury or property damage during
system operation. AME cannot be responsible for damage or
injury resulting from unsafe product use, lack of maintenance or
incorrect product and/or system operation. Contact AME when
in doubt as to the safety precautions and operations. If you have
never been trained on high-pressure hydraulic safety, consult
your distribution or service center for a free AME Hydraulic safety
course.
Failure to comply with the following cautions and warnings could
cause equipment damage and personal injury.
A CAUTION is used to indicate correct operating or maintenance
procedures and practices to prevent damage to, or destruction
of equipment or other property.
A WARNING indicates a potential danger that requires correct
procedures or practices to avoid personal injury.
A 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 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.
pressure of 700 bar [10,000 psi]. 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.
CAUTION: Air Hydraulic Pumps and all tire tools
should be used only by persons properly trained
according to OSHA regulation No. 29CFR1910.177,
"Servicing Single-piece and Multi-piece Wheels."
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 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
hoses or swivel couplers. Use the carrying handle or
other means of safe transport.
15040
15020
15000

2
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 packings. 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 SETUP IS STABLE BEFORE
LIFTING 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.
IMPORTANT: Hydraulic equipment must only be
serviced by a qualified hydraulic technician. For repair
service, contact the Authorized AME Service Center in
your area. To protect your warranty, use only AME oil.
WARNING: Immediately replace worn or damaged parts by
genuine AME parts. Standard grade parts will break causing
personal injury and property damage. AME parts are
designed to fit properly and withstand high loads.
3.0 DESCRIPTION
The 10,000 psi 15000 Air Pumps have an operating pressure
of 10,000 psi at 85 psi inlet pressure. They are suited for
plant maintenance, fabrication, production, bolting, vehicle
repair, and any task that requires hydraulic pressure from air
input.
4.0 SPECIFICATIONS
See table below.
5.0 INSTALLATION
5.1 Air Supply
Pump operates with 25-125 psi [1,7-8,6 bar] air pressure. A regulator/
filter/lubricator should be installed upstream from pump to provide
clean, lubricated air and allow for air pressure adjustment.
5.2 Air Connections
See Figure 1, page 5. Attach air supply to the 1/4 NPT swivel
connection on the end of the pump. Use Teflon tape or similar
thread sealant. Torque to 20-25 ft. lbs [27-34 Nm].
5.3 Hydraulic Connections
See Figure 2, page 5. Thread hose(s) into outlet port of pump (A).
Hose fittings must be torqued.
NOTE: Use 11/2 wraps of Teflon tape the NPTF hose fittings
only, leaving the first complete thread free of tape to ensure that
pieces of tape do not break off and enter the system. Torque: 65-
75 Ft-lbs [88-102 Nm].
NOTE: Valve block or treadle should be restrained when
torquing fittings. The reservoir base should not be bolted down
or restrained to compensate for the fitting installation torque.
5.4 Venting
This pump must always be vented prior to use. Use either the
"Vent Screw" or "Vent/Fill Plug".
a) Vent Screw: See Figure 3, item 1, page 5. The vent screw is the
primary means to vent the reservoir when the pump is operated
in the horizontal position. It is located near the hydraulic outlet
port on top of the reservoir. To use this plug, open the screw
1-2 turns. To avoid damaging the threads when closing the
vent screw, tighten only until screw head contacts the reservoir
cover. The vent screw can NOT be used when pump is mounted
vertically! When mounting in the vertical position, use the vent/
fill plug.
b) Vent/Fill Plug: See Figure 4, item 2, page 5. The Vent/Fill plug
is located on the air inlet end of the pump, opposite the vent
screw. This plug serves 3 functions; vent plug, fill port, and
return-to-tank port.
Hydraulic
Air Ratio
Hydraulic
Output Ports
Oil Flow @
100 psi
(6.9 bar)
Oil Flow @
10,000 psi
(700 bar)
Air Pressure
Range
Air
Consumption
100 psi
(6.9 bar)
Operating
Noise Level
(dBA)
100:1 .375-18 NPTF 60 cu.in/min.
(1.0 liters/min.)
10 cu.in/min.
(0.16 liters/min.)
25-125 psi
( 1,7-8,6 bar)
12 SCFM
(0.34 cu.m/min)
76
Model
No. Weight-add 1 lb. (.5 kg) for bracket
Reservoir
Capacity Useable Oil Horizontal Mount
Usuable Oil
Vertical Mount
15000 18 lbs. [8,2 Kg] 150 cu.in 127 cu.in 70 cu.in
(2.5 liters) (2.1 liters) (1.2 liters)
15020 22 lbs. [10,0 Kg] 255 cu.in 230 cu.in 180 cu.in
(4.2 liters) (3.8 liters) (3.0 liters)
15040 40 lbs. [18,1 Kg] 2.11 Gal 1.85 Gal. N/A
(8.0 liters) (7.0 liters) N/A
SPECIFICATION TABLES

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To use as a vent (for vertical applications or temporary venting)
pull up on hex plug until first detent is reached (see Figure 5). This
is the vented position.
To use as a return-to-tank port, remove flush plug from hex and
install compatible return line. Torque return line to 15-20 ft. lbs.
[20-27 Nm] in hex plug.
CAUTION: Pump reservoir must be vented using one
of the two vent options. Failure to do so may cause
cavitation and pump damage.
5.5 Mounting Pump
15000:Pump can be mounted horizontally or vertically. If
mounted vertically, position pump with hydraulic outlet port(s)
facing down.
15000 and 15020:The four holes in the bottom of the
reservoir should be used for bolting through the mounting surface
into the reservoir. Use the #10 x 5/8" fasteners included with
pump, or allow no more than 3/4" [19 mm] thread engagement
into reservoir.
CAUTION: When mounting the pump in the vertical
position, the vent screw must remain closed.
15040:The U-shaped mounting rails on the bottom of the
reservoir have four .26 in. [6,6 mm] holes for mounting.
5.6 Oil Level
Always check oil level with all cylinders or tools in the fully
retracted position. If they are advanced when the pump is fi lled,
the reservoir will be over-filled when they are retracted.
Use the low-level sight glass on the end of the pump to check the
oil level. When the pump is mounted horizontally, the reservoir
is full when oil is at the bottom of the fill port. If oil is not visible,
then oil must be added. To add oil, remove Vent/Fill plug from
reservoir (See section 5.4b).
When the pump is mounted vertically, 15000 the oil level should
be checked periodically by removing the pump and placing it
on a horizontal surface.
NOTE: Prior to mounting the 15000 pump in the vertical position, oil
volume in the reservoir must be reduced to 127 in3 [2,1 L] prevent
leakage through the vent/fill plug. See the specification table on page
2 for usable oil capacity in vertical position.
6.0 OPERATION
6.1 Oil Level
Check the oil level of pump and add oil if necessary (See
Installation section, step 5.6).
6.2 Venting Pump
Make sure the pump reservoir is vented (See Installation section,
step 5.4).
6.3 Treadle Operation
See figure 6.
a) To Advance Cylinder: Depress the "PRESSURE" end of treadle
and the pump will start to pump hydraulic oil to the system.
b) To Hold The Cylinder Position: The pump will stop and hold
pressure when the treadle is in the free/neutral position (treadle is
not depressed in either "PRESSURE" or "RELEASE" positions.)
c) To Retract Cylinder: Depress the "RELEASE" end of the treadle
to retract cylinder. To stop the cylinder from retracting, release
the treadle and return it to the hold position.
6.4 Priming
Priming of the hydraulic pump is normally not required. If the
air motor runs very fast, but no hydraulic pressure is built, the
pump may have lost its prime. This pump can lose prime if it
is run completely out of oil or if an air bubble is trapped in the
pumping chamber. An air bubble could occur during shipment,
or when the shipping plug is removed while the pump is held in
the vertical (shipping plug up) position.
a) Place the pump on a flat, horizontal surface. Remove the
shipping plug only when in a horizontal position! Attach
an approved 10,000 psi rated hydraulic hose and cylinder
assembly to the hydraulic outlet 3/8” NPT port. Torque fittings
to 65-75 ft.lbs. (88-102 Nm.)
b) Attach air supply to the 1/4” NPT swivel connection. Torque to
20-25 ft. Lbs (27-34 Nm.).
c) Fill pump with only high-quality hydraulic Oil, 32 cSt hydraulic oil.
d) Prime the pump with air pressure set to 30-40 psi. If air pressure
is different than 30-40 psi follow the procedure below:
e) ON MODELS WITH TREADLE: While holding the treadle down
firmly in the RELEASE position, slowly depress the PRESSURE
button located under the toe of the treadle near the air supply
fitting. Try to get the air motor to operate one or two cycles
at a time. Slowly depressing the PRESSURE button will allow
you to “throttle” the inlet air pressure
f) Pressing the operating buttons in this manner effectively draws
oil through the intake tube to refill the pressure chamber. You
may need to hold the treadle and “throttle” the PRESSURE
button for a few minutes to completely remove the air and
prime the pump models with an air pendant, hold "RET" button
down while cycling
g) ON MODELS WITH 4-WAY VALVES: Shift valve to neutral position,
press the treadle, and run the pump momentarily several times.
h) On models with an air pendant, hold “RET” button down while
cycling “ADV” button momentarily several times.
i) To verify that the pump is primed, operate as normal with
cylinder attached. If cylinder does not advance, repeat step
6.4g or 6.4h.
7.0 MAINTENANCE
7.1 Maintaining Proper Oil Level
Check the oil level of the pump prior to start-up, and add only
high-quality hydraulic oil, if necessary, by removing the vent/fill
plug (refer to Installation section, step 5.6).
7.2 Cleaning The Muffler
Clean the muffler every 250 hours, or more frequently if pump
is used in dirty environments. First remove 2 shoulder bolts (A)
and treadle (B). See Figure 7. To expose the muffler, remove
2 screws (C) holding down muffler plate. See Figure 8. Wash
muffler element in soapy water, dry, and reassemble, installing
screws hand tight.
7.3 Changing The Oil
Change the oil every 250 hours. The vent/fill plug serves as a
drain plug for use in changing oil. Refill pump with only high-
quality hydraulic oil. Dispose of used oil properly.
7.4 Cleaning The Air Inlet Filter
Remove the swivel air connector by removing the two cap screws
and pulling air filter out of cavity. Using an air nozzle blow debris
off filter. (Always use proper eye protection). Re-install filter and
swivel connector. Torque cap screws to 16-18 in.lbs [1,8-2,0 Nm].

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PROBLEM CAUSE
1) Pump will not start Air turned off or line blocked
2) Motor stalls under load Low air pressure*
Inlet filter plugged, insufficient air flow
3) Pump fails to build pressure External leak in system
Internal leak in pump
Internal leak in system component
Low oil level
4) Pump builds less than full pressure Low air pressure*
Internal relief valve set low
External system leak
Internal leak in system component
5) Pump builds pressure, but load does not move Load greater than cylinder capacity at full pressure
Flow to cylinder blocked
6) Cylinder drifts back on its own External system leak
Internal leak in system component
7) Cylinder will not return A) Single-acting type Return flow or coupler restricted/blocked
No load on a "load return" cylinder
Return spring broken on cylinder
Release Valve Malfunction
B) Double-acting type Return flow or coupler restricted/blocked
Valve malfunction
8) Low oil flow rate Reservoir not vented
Inadequate air supply
Dirty air filter
Clogged inlet filter
* 85 psi (5,86 Bar) air pressure required to obtain 10,000 psi (700 Bar) hydraulic pressure.
8.0 TROUBLESHOOTING
Only qualified hydraulic technicians should service the pump
or system components. A system failure may or may not be
the result of a pump malfunction. To determine the cause of
the problem, the complete system must be included in any
diagnostic procedure. The following information is intended to
be used only as an aid in determining if a problem exists. DO
NOT disassemble the pump.

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CLOSED VENTED
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