MAXIMATOR GX35 User manual

Operating instructions
MAXIMATOR Pump
Types GX35, GX60, GX100
MAXIMATORGmbH
D-37449 Zorge / Südharz
Phone: [phone]
Fax: [phone]

Attention!
These operating and maintenance instructions for a MAXIMATOR product
have been prepared for operators.
The instructions will defeat their purpose when they are not passed on to
system operators and are not studied and used.
The documentation prepared by us reflects the current manufacturing status.
We reserve minor design changes.
If an operator fails to understand any of the instructions we invite them to call
us and quote the relevant serial No. indicated in the cover sheet of this
documentation and in the machine plate.
MAXIMATORGmbH
D-37449 Zorge / Südharz
Tel.: [phone]
Fax: [phone]

Important!
We as the manufacturer of this product have taken account of the fundamental health and
safety requirements during the design and fabrication of the entire product.
The owner of the system has to see to it that the operating personnel will continue to
adhere to the applicable regulations during any required work.
Specific requirements are laid in the following standards:
- EC Machine Directive in the version 98/37/EG
- EC Pressure Equipment Directive 97/23/EC
- EN 292-1 Machinery safety - Basic concepts, general principles for design.
- Part 1: Basic terminology, methodology.
- EN 292-2 Machinery safety - Basic concepts, general principles for design.
Part 2: Technical principles and specifications.
- EN 294 Machinery safety, Safety distances to prevent danger zones from being
reached by the upper limbs.

Table of contents
1. Operating instructions for MAXIMATOR pumps
1.1 Technology
1.2 Technical data
1.4 Wearing part kits
1.5 Performance curve GX35
1.6 Performance curve GX60
1.7 Performance curve GX100
2. Mode of operation
2.1 Drive part
2.2 Control part
2.3 High-pressure part
3. Safety
4. Maintenance
5. Repair instructions
5.1 Replacement of high-pressure sealings
5.2 Replacement of control sealings
5.3 Sealing replacement at the drive side
6. Troubleshooting
6.1 Compressed air system
6.2 Hydraulic system
7. Warranty
8. General instructions
8.1 Compressed air quality
8.2 Compressed air lubrificator Yes or No
8.3 Re-greasing of servovalves

1. Operating instructions for MAXIMATOR pumps
Type GX35; GX 60; GX 100
1.1 Technology
The MAXIMATOR Pump described below is a slide-valve piston that is driven by gaseous
media and has been especially conceived for offshore applications. It can be employed in
the pumpage and compression of water or oil. Its construction resembles a pneumatic
cylinder.
The pump coefficient denotes approximate ratio between drive pressure and working
pressure.
The connection for the drive medium (Marking P
L
) is located at the bottom cap of the
flanged-on servovalve casing to which also the silencers are fixed. The pressure nozzle
(Marking P) is located laterally at the HP location of the pump.
The pumps are designed in such a manner that medium is pumped in both travel
directions of the HP piston which provides them with a high pump capacity. The intake
(Marking S) is arranged in longitudinal direction. The bottom cap has a bore to discharge
any leakages of the drive or compression medium.
The pump runs automatically and is driven by a floating slide valve that reciprocally admits
pressure or vents the drive piston. The control system operates without any springs or
interlocking because pressure is admitted reciprocally the floating slide valve.
Major components of the hydraulic part are the pump head, piston rod with HP piston, HP
sealings with back-up rings and the non-return valve at the suction connection.

1.3 Technical Data
GX 35 GX 60 GX100
Air piston diameter 6.30" (160 mm)
Length of stroke 4.33" (110 mm)
Piston diameter 1.42"
(36 mm)
1.10"
(28 mm)
0.83"
(21 mm)
Pressure ratio 1 : 36 1 : 65 1 : 117
Piston capacity 10.98 cu.in
(180 cm³)
3.97 cu.in
(65 cm³)
2.20 cu.in
(36 cm³)
Max. working pressure 5220 psi
(360 bar)
8700 psi
(600 bar)
14500 psi
(1000 bar)
Max. drive pressure 145 psi (10 bar)
Air connection (PL) 3/4 FNPT
Suction connection (S) 1 FNPT
Pressure outlet (P) 3/8 FNPT
Length approx. 24.88" (ca. 632 mm)
Width approx. 9.33" (ca. 237 mm)
Height approx. 9.60" (ca. 244 mm)
Weight approx. (ca.) 24 kg
Max. operating temperature approx. (ca.) 50 °C
1.4 Wearing part kits
GX 35 GX 60 GX 100
Servovalve 3620.2029 3620.2029 3620.2029
Air drive part 3620.1742 3620.1742 3620.1742
High-pressure part 3620.2155 3620.2195 3620.2198

1.5 Performance curve of MAXIMATOR pump
Type GX35

1.6 Performance curve of MAXIMATOR pump
Type GX60

1.7 Performance curve of MAXIMATOR pump
Type GX100

2. Mode of operation
As a rule, the pump may be operated in any position but the longest service life of
sealings is ensured when it is installed vertically.
2.1 Drive part
The drive part consists of an air cylinder (22), bottom cap (20), top cap (26) and
air piston (48) to which compressed air is admitted reciprocally that prompts it to
make an oscillating motion.
In its stop positions the air piston (48) actuates the pilot valve plungers (53,85).
These pilot valves control the servovalve (31) by means of compressed air.
The pump is driven with compressed air (other gases upon request). When
compressed air is employed as drive we recommend our maintenance unit,
consisting of a filter, water separator, shut-off valve, pressure controller and
master pressure gauge.
If the maintenance unit is not installed, a suitable filter with a 5 µm mesh should
be used.
A lubrificator is not required since the pump is treated with a high-performance
grease prior to shipment.
If a lubrificator is provided in the drive system, a silicon- and acid-free oil should
be used to avoid swelling of packing rings. A pump that is equipped with a
lubrificator may only be used in lubrificator-equipped systems.
2.2 Control part
The control part consists of the servovalve (31), and servovalve runner (35), all
accommodated in the servovalve casing (83).
The servovalve (31) is actuated with compressed air by the pilot valves (53,85). The
servovalve feeds drive air to the right or left side of the air drive piston (48).

2.3 High-pressure part
The pump is envisaged for pumpage and compression of water or oil. The hydraulic
pressure can be determined by adjustment of the drive pressure.
Please, use the attached diagram for this purpose (Technical Data). The piston
frequency decreases with rising hydraulic pressure. Operate the pump at a low
frequency until the pump is fully primed with fluid and the hydraulic system is
ventilated.
The hydraulic pipework and accoutrements should be matched to the pump as
regards their pressure, cross-section and medium. The nominal width of pipework
should not be dimensioned smaller than the connection cross-section of the pump.
The suction diameter may only be reduced when fluid is charged under pressure.
The suction pipeline should be equipped with filter with a mesh size of max. 100µm.

3. Safety
The design of MAXIMATOR pump is based on the generally accepted engineering
standards and on the laws relating to technical equipment safety, TÜV [German Technical
Inspectorate] regulations as well as the accident prevention regulations of the German
Employers' Liability Insurance Association [Berufsgenossenschaft].
Those codes and regulations must also be adhered to during installation and application
of the pumps.
Only the specified media may be used both at the drive- and the compression-side.
The hydraulic pipework and accoutrements should be matched to the system pressure
and the medium and be of appropriate sizes.
The pressure of the drive medium must not exceed 10 bar.
Make sure to vent the hydraulic part of the pump prior to start-up. Check secure fastening
of all fixed pipework in order to prevent fatigue pipe fractures during pump operation.
Do not loosen the hydraulic bolted union at the suction and pressure nozzles to facilitate
installation of pipe connections. These bolted unions must be firmly tightened to prevent
leakages and damage.
The pump must NOT be installed in enclosed containers because the drive medium must
be able to escape.
Repair work may only be performed after the system has been depressurised.
Make sure to observe all relevant safety regulations when the pump is driven with
explosive media. The connections must be tight and the depressurised medium from the
exhaust pipe, the leakage bore and the venting bore in the top cap must be safely
disposed of.

4. Maintenance
The air drives of all fluid pumps are pre-treated with high-performance grease and do not
require any other kind of lubrication. In order to extend the service life of the piston rod
sealing the grease filling should be topped up after 14 days of operation. Use the
lubricating nipple at the bottom cap. Only during overhauls of the pump, the servovalve
and drive piston should be treated with acid- and silicon-free grease. We recommend the
use of a MAXIMATOR grease.
5. Repair instructions
Please, use for a necessary repair only original MAXIMATOR spare parts, otherwise the
proper functioning may be impaired. Ensure the highest possible level of cleanliness
during servicing work at the pump in order to ensure both the proper functioning and
service lives of the precision-machined parts.
Ensure the same torques for the nuts of the four stud bolts during assembly in order to
avoid distortions of the top and bottom caps.
5.1 Replacement of high-pressure sealing
Depressurise the pump and disconnect all tube connections from the pump.
Dismantle the pipeline 1 (Item 58).
Remove the four hexagon socket screws (Item 69).
Now the pump head (Item 71) can be drawn off to the front.
After dismantling of the pump head the two dowel pins (Item84 and 85) can be
removed.
Now the pressure section (Item 1) can be dismantled.
Then the HP piston can be unscrewed.
The sealings can be replaced.

5.2 Replacement of servovalve sealings
Depressurise the pump and disconnect all tube connections from the pump.
Loosen the bolted union at the pipeline (Item 45).
Loosen the 8 hexagon bolts and disassemble the covers of the servovalve
(Item 30 and 40).
Draw out the servovalve (Item31) and disassemble the O-rings (Item 33,38
and 39).
Use a mandrel (PTFE or wood) to force out the servovalve runner (Item 35)
and remove the O-rings (Item 34).
Treat all sealing and guiding elements with a resin- and acid-free grease. Re-
assembly is performed in reverse order than disassembly.
5.3 Sealing replacement at the drive side
Depressurise the pump and disconnect all tube connections from the pump.
Disassemble the union nut (Item 18) and the pipe (Item 19).
Loosen and remove the 4 hexagon nuts (Item 28).
Disassemble the pipeline (Item 45) and the hexagon bolts (Item 29 and 46).
Disassemble the pipelines (Item 58 and 79) from the top and bottom caps.
Now the top cap (Item 26) and the air cylinder (Item 22) can be drawn off.
Treat all sealing and guiding elements with a resin- and acid-free grease. Re-
assembly is performed in reverse order than disassembly.

6. Troubleshooting
6.1 Compressed air system
Symptom Cause Remedy
Excessive friction of O-rings on
servovalve
Re-greasing or renewal of O-
rings at the servovalve
Pump fails to run at low
drive pressure Swelling of O-rings due to
wrong oil or lubricant
Replacement of O-rings, use
acid- and silicon-free
lubricant
Iced exhaust pipe or
servovalve
Use water separator to
dehydrate compressed air
Pump fails to run or runs
only slowly Forming of deposits in the
silencer
Cleaning of silencer
Defective O-rings at
servovalve
Exchange and grease O-
rings
Pump fails to operate and
drive medium escapes via
the exhaust pipe Defective or worn out sealing
at drive piston
Exchange and grease
sealings
Pump operates at high
frequency and with short
strokes
Defective pilot valve in top or
bottom cap
Check pilot valve, if need be:
clean, grease and replace
6.2 Hydraulic system
Symptom Cause Remedy
Air in hydraulic system Vent the system
Check tightness of suction
pipelines and bolted unions.
Suction pipeline too long Shorten the suction pipeline
as much as possible
Suction cross-section too
small
Extend the cross-section,
otherwise the suction flow is
disrupted
Failures of suction or non-
return valves in HP piston
Check both valves, if need
be: clean and replace
Suction filter is clogged Clean suction filter
Pump operates without
conveying medium or
operates irregular or fails to
achieve the arithmetic final
pressure
Worn off HP sealing Replace sealing set at HP
piston
Fluid escapes via the
exhaust pipe
Worn off HP sealing der
piston rod
Replace sealing set

7. Warranty
The pump described above has a warranty for material quality and fabrication
workmanship of twelve (12) months, commencing upon the original shipment date.
This warranty does not include packaging, sealings, defects due to improper handling or
failure due to uses of unauthorised fluids, foreign matter in the drive or conveying medium
or application of excessive pressures.

8. General operating instructions for a MAXIMATOR pump
8.1. Compressed air quality
Drive air should have a quality grade of 3 to 4 (solids/water/oil), i.e. the following
contents as defined in the PNEUROP recommendation 611/1984 (PNEUROP =
European Committee of Manufacturers of Compressors, Vacuum Pumps and
Compressed Air Equipment).
Solids: Max. particle size 5 micron
Max. particle concentration 5 mg/m
3
Pressure dew point: +10°C = Water content 9.4 g/m
3
to
+2°C = Water content 5.6 g/m
3
Oil content: 1.0 to 5 mg/m
3
The above-mentioned compressed air quality ensures an optimal service life of
sealing and guiding elements.
8.2 Compressed air lubrificator Yes or No
The following problems may occur when MAXIMATOR pumps are operated with
dried drive air (dew point below -10°C):
* Dried drive air may cause the hardening of installation lubricant. This may result in
malfunctions in the control and drive parts of the pump.
The following measures should be initiated.
-Install a mist lubrificator the drive air pipeline. This mist lubrificator feeds a
precisely proportionable oil volume to the compressed air. The drop quantity
should be 1 to 8 drops per 1000 litres of compressed air.
The following oils may be used.
-Avia Avilub RSL 10
-BP Energol HLP 10
-Blaser Blasol 154
-Esso Spinesso 10
-Mobil DTE 21
-Shell Tellus oil C10

Important advice:
When a MAXIMATOR pumps is operated with a lubrificator the drive air must
always be oil (The oil washes the installation lubricant off sealing and guiding
elements).
OR
the pump should be returned to the manufacturer in order to perform a new
assembly lubrication.