Milwaukee Cylinder DuroTech, MAP07, MAP15, MAP30 Instructions Manual

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Page 1

MAP-IS Rev. A 03/18

Table of Contents:

Section Page

1.0 IMPORTANT RECEIVING INSTRUCTIONS . . . . . .1

2.0 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

3.0 PRODUCT DESCRIPTION . . . . . . . . . . . . . . . . . . .4

4.0 PRODUCT DATA . . . . . . . . . . . . . . . . . . . . . . . . . . .4

5.0 INSTALLATION AND SETUP . . . . . . . . . . . . . . . . .6

6.0 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

7.0 INSPECTION, MAINTENANCE & STORAGE . . . . .9

8.0 ROUTINE MAINTENANCE PROCEDURES . . . . . .9

Instructions Sheet

Milwaukee Cylinder DuroTech™ Series

Air-Driven Hydraulic Pumps

MAP07, MAP15 and MAP30*

9.0 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . .14

*MAP30 available as a special only. Please contact Milwaukee

Cylinder customer service for details.

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.

2.0 SAFETY

2.1 Introduction

Read all instructions carefully. Follow all recommended safety precautions to avoid personal injury as well as damage to the product and/or damage to other property. Milwaukee Cylinder cannot be responsible for any damage or injury from unsafe use, lack of maintenance or incorrect operation. Do not remove warning labels, tags, or decals. In the event any questions or concerns arise, contact Milwaukee Cylinder customer service representative.

This manual follows a system of safety alert symbols, signal words and safety messages to warn the user of speciﬁ c hazards. Failure to comply with these warnings could result in death or serious personal injury, as well as damage to the equipment or other property.

The Safety Alert Symbol appears throughout this manual. It is used to alert you to potential physical

injury hazards. Pay close attention to Safety Alert Symbols and obey all safety messages that follow this symbol to avoid the possibility of death or serious personal injury.

Safety Alert Symbols are used in conjunction with certain Signal Words that call attention to safety messages or property damage messages and designate a degree or level of hazard seriousness. The Signal Words used in this manual are WARNING, CAUTION and NOTICE.

WARNING

CAUTION

NOTICE

Indicates a hazardous situation that, if not

avoided, could result in death or serious personal injury.

Indicates a hazardous situation that, if not

avoided, could result in minor or moderate personal injury.

Indicates information considered important,

but not hazard related (e.g. messages relating to property damage). Please note that the Safety Alert Symbol will not be used with this signal word.

2.2 Hydraulic Pump Safety Precautions (DuroTech Series)

WARNING

Failure to observe and comply with the following precautions could result in death or serious personal injury. Property damage could also occur.

• Read and completely understand the safety precautions and

instructions in this manual before operating the pump or preparing it for use. Always follow all safety precautions and instructions, including those that are contained within the procedures of this manual.

• Operating procedures will vary, depending on the system

arrangement and the speciﬁ c components being used. Always read, follow and completely understand all manufacturer's instructions when operating cylinders, valves and any other hydraulic devices used with the pump. Follow all safety precautions contained in the manufacturer's manuals.

• Always wear appropriate personal protective equipment

(P.P.E.) when operating hydraulic equipment. Be sure to wear eye protection, work gloves and protective clothing. Use of additional P.P.E. safety items such as dust mask, non-

Page 2

skid safety shoes, hard hat, and hearing protection (used as appropriate for the conditions) will reduce the chance of personal injuries. The use of these items may also be required by local regulations or laws.

• Do not handle pressurized hoses. Escaping oil under pressure can penetrate the skin. If oil is injected under the skin, see a doctor immediately.

• Do not pressurize disconnected couplers.

• Only use hydraulic cylinders in a coupled system. Never use a cylinder with uncoupled couplers. If the cylinder becomes extremely overloaded, components can fail catastrophically, causing severe personal injury.

• The pump is equipped with a hydraulic safety relief valve that is factory preset to the pump's maximum operating pressure. DO NOT attempt to adjust, bypass or alter the safety relief valve. This valve is not user-adjustable.

• The system operating pressure must not exceed the pressure rating of the lowest rated component in the system. Refer to Section 4.1 of this manual for the maximum rated working pressure for your pump model.

• Install pressure gauge(s) in the system to monitor operating pressure. It is your window to see what is happening in the system.

• Never set the pump hydraulic pressure to a higher setting than the maximum rating of the hoses and connected devices. The pressure setting should not exceed the setting of the lowest rated component (pump, cylinder or other hydraulic component) in the circuit.

• Do not exceed equipment ratings. Overloading may cause equipment failure and possible personal injury.

• Always perform a visual inspection of the pump before placing it into operation. If any problems are found, do not use the pump. Have the pump repaired and tested before it is returned to service.

• Fill the pump reservoir with hydraulic oil only to the recommended level. Fill only when cylinders (or other hydraulic actuators) are in their normal de-energized position.

• Never use the pump if it is leaking oil. Do not use the pump if it is damaged, has been altered or is in need of repair.

• Always lift the pump using only the provided lifting handles.

• Allow only trained and experienced personnel to operate the pump.

• Be certain that hydraulic pressure is fully relieved from the cylinder (or other hydraulic actuator) before disconnecting hydraulic hoses, loosening hydraulic ﬁ ttings, or performing any disassembly or repair procedures.

• If hydraulic equipment is damaged, do not touch or go near any area where high-pressure oil is spraying. Promptly stop usage of the hydraulic equipment and replace the damaged parts with new ones before using the equipment again.

• Do not put your hands or body in line with the face of a disconnected coupler. If the coupler becomes pressurized and leakage occurs, the high-pressure oil stream could penetrate the skin.

• Skin penetration from high-pressure hydraulic oil can result in death or serious personal injury. If oil is injected under the skin, see a doctor immediately.

CAUTION

Failure to observe and comply with the following precautions could result in minor or moderate personal injury. Property damage could also occur.

• Be careful to avoid damaging hydraulic hoses. Avoid sharp bends and kinks when routing hydraulic hoses. Do not exceed the minimum bend radius speciﬁ ed by the hose manufacturer. 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 hoses. A sharp impact may cause internal damage to hose wire strands. Applying pressure to a damaged hose may cause it to rupture.

• Do not lift hydraulic equipment by the hoses or couplers.

• Make sure that all system components are protected from external sources of damage, such as moving machine parts, sharp edges and corrosive chemicals.

• Keep hydraulic equipment away from ﬂ ames. Flames near a hydraulic oil leak could cause the hydraulic oil to ignite, resulting in a ﬁ re.

• For optimum performance, do not expose hydraulic equipment to temperatures of 150˚F [65˚C] or higher. Excessive heat will soften packings and seals, resulting in possible hydraulic ﬂ uid leaks.

• Protect all hydraulic equipment from weld spatter.

• Protect the pump against rain, mud, dust, and humidity when using it outdoors.

• Disconnect air supply hose when pump is not in use for a prolonged period of time. NEVER remove a swivel air connector while the air hose is pressurized.

• Immediately replace worn or damaged parts with genuine Milwaukee Cylinder parts. Milwaukee Cylinder parts are designed to ﬁ t properly and to withstand high loads. NonMilwaukee Cylinder parts may break or cause the product to malfunction.

NOTICE

• Hydraulic equipment must only be serviced by a qualiﬁ ed hydraulic technician. For repair service, contact Milwaukee Cylinder customer service representative.

• To help ensure proper operation and best performance, use only genuine Enerpac hydraulic oil.

2.3 Additional Safety References

Consult the applicable industry and/or government standards in your country or region for additional safety precautions and work rules applicable to hydraulic pumps, hydraulic devices

and related components.

3.0 PRODUCT DESCRIPTION

The Milwaukee Cylinder DuroTech Series Air Driven Hydraulic Pump is intended for high-use, high-ﬂ ow industrial applications.

Three di erent maximum pressure ratings are available to suit a wide variety of user requirements.

Each valve manifold contains four stations, allowing for up to four control valves to be installed. Control valves are available from Milwaukee Cylinder or Enerpac (sold separately).

The dual action pump element combines smooth operation with maximum durability. A built in air ﬁ lter/regulator allows easy adjustment of pump hydraulic pressure and helps protect the pump air components from containments.

The large 1.8 gallon [6.8 liter] hydraulic reservoir provides ample oil capacity to power multiple hydraulic devices.

A removable metal shroud allows easy access to the pump element for routine inspection and maintenance activities.

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Key:

1. Hyd. Pressure Gauge

2. Cover Plate/Valve Station

3. Hyd. Manifold

4. Hyd. Hose Ports

5. Hyd. Reservoir

6. Drain Plug

7. Sight Gauge

8. Vent Screw

9. Hyd. Pressure Sensor Port

10. Carrying Handle

11. Hyd. Oil Fill Plug

12. Air On-O Control

13. Metal Shroud

14. Mounting Hole

15. Air Pressure Gauge

16. Air Pressure Control

17. Air Inlet Connection

Figure 1 - Major Features and Components

Page 4

4.0 PRODUCT DATA

4.1 Speciﬁ cations, Pressure, Flow and Air Consumption

Hydraulic Pressure

Pump

Series

MAP07 1920 132 1595 110 2000 138 16:1 612 10.0 30-120 2.0-8.2 24 0.68

MAP15 2760 190 2320 160 3000 207 23:1 465 7.6 30-120 2.0-8.2 24 0.68

MAP30 5280 364 4785 330 5500 379 48:1 252 4.1 30-110 2.0-7.6 20 0.57

1) Based on 120 psi [8.3 bar] air pressure for the MAP07 and MAP15 Series, and 110 psi [7.6 bar] air pressure for the MAP30 Series.

2) At zero (0) psi/bar hydraulic pressure.

Max. Hyd.

Working

Pressure

psi bar psi bar psi bar - in

Max. Hyd.

Pressure

@100 psi Air

[6.9 bar]

Hyd. Safety Relief Valve

Setting

Pressure

Ratio

Hydraulic

to Air

Max. Hydraulic

Flow

@100 psi Air

[6.9 bar]

/min l /min psi bar scfm m³/min

Air Pressure

Range

Max Air

Consumption

@ 100 psi Air

[6.9 bar]

4.2 Additional Speciﬁ cations

Pump Series

MAP07 MAP15 MAP30

Reservoir Usable

Oil Capacity

Gallons in

1.8 415 6.8

Approximate Weight

Hydraulic Oil

Liters Type lb kg °C °F dBA

Enerpac HF

(Refer to Section 5.3)

(not including

hydraulic oil or

control valves)

71 32.2 0 to 60 32 to 150 75

Operating

Temperature

Range

Sound Level

Pump Series Air inlet connection Hydraulic Hose Connection Hydraulic Valve Manifold Station

MAP07 MAP15 MAP30

1/4" NPT #8 SAE D03 4

4.3 Schematic Diagram

Description of Operation:

Air is automatically ported and vented to the pump piston. The piston plunger contains a pressurizing ram at each end. Every time the piston moves, one of the rams sends pressurized hydraulic oil to the manifold.

Shop air is connected to the builtin pressure regulator, allowing the operator to adjust the air pressure, that in turn sets the maximum hydraulic oil pressure.

The air is ported through a builtin shut-o valve. With the shut-o valve open, the pump automatically starts and stops to obtain and then maintain the customer selected pressure.

Number of

Stations

Page 5

4.4 Pump Dimensions

Item inch mm

A 8.9 226

ø 0.31

0.09

C 2.0 51

D 15.8 401

E 13.2 335.2

F 16.6 421.6

G 12.7 332.6

7.9 x

2.3

BABABAB

4.5 Performance Curves (hydraulic pressure vs. ﬂ ow)

Imperial

900

800

700

600

/min) X

500

400

300

Oil ﬂow (in

200

100

0 200 400 600 800 1000 1200 1400 1600 1800

Hydraulic Pressure (psi)

60 psi 80 psi 100 psi

Air pressure

700

600

500

/min) X

400

300

200

Oil ﬂow (in

100

0 500 1000 1500 2000 2500 3000

Hydraulic Pressure (psi)

60 psi 80 psi 100 psi

Air pressure

MAP07 Series MAP15 Series MAP30 Series

350

300

250

/min) X

200

150

100

Oil ﬂow (in

0 1000 2000 3000 4000 5000 6000

Hydraulic Pressure (psi)

Metric

14.8

13.1

11.5

9.8

8.2

6.6

4.9

Oil ﬂow (l/min) X

3.3

1.6

0 14 28 41 55 69 83 97 110 124

Hydraulic Pressure (bar)

4.1 bar

5.5 bar

6.9 bar

Air pressure

11.5

9.8

8.2

6.6

4.9

3.3

Oil ﬂow (l/min) X

1.6

0 34 69 103 138 172 207

Hydraulic Pressure (bar)

4.1 bar

5.5 bar

6.9 bar

Air pressure

5.7

4.9

4.1

3.3

2.5

1.6

Oil ﬂow (l/min) X

0.8

0 69 138 207 276 345 414

Hydraulic Pressure (bar)

WAP07-Hydra

60 psi 80 psi 100 psi

Air pressure

4.1 bar

5.5 bar

6.9 bar

Air pressure

MAP07 Series MAP15 Series MAP30 Series

NOTICE

Performance will be signiﬁ cantly diminished if air pressure falls below 50 psi [3.4 bar]. Actual performance may vary

from values shown, due to seal friction, internal pressure drops and manufacturing tolerances.

Page 6

5.0 INSTALLATION AND SETUP

5.1 Mounting

Install the pump on a solid and level horizontal surface that is capable of supporting the weight of the pump, control valves and any associated equipment.

Four slotted mounting holes are provided on the pump bottom ﬂ ange. See Figure 2. Secure the pump with 5/16" SAE or M8 ISO screws (user supplied).

Figure 2 - Mounting Holes

NOTICE

(with the pump bottom ﬂ ange facing down). To avoid damage to pump and possible oil leakage, do not attempt to mount the pump on a wall or other vertical surface.

Pump must be operated only in the horizontal position

5.2 Valve Installation

Control valves are sold separately and are not included with the pump. Refer to the Milwaukee Cylinder website or catalog for a description of available control valves and related accessories. Consult Milwaukee Cylinder if additional valve selection guidance is needed.

NOTICE

Milwaukee Cylinder DuroTech Series pumps.

When installing control valves, always work in a clean and dry area. Take all appropriate precautions to avoid contamination and dirt entry. Follow the valve manufacturer's instructions carefully to ensure proper installation. Be sure that the cover plates remain tightly installed over all unused valve stations. See Figure 3.

The Milwaukee Cylinder cross over cover plate (optional accessory) can be used to covert A and B outlet ports to P and T ports for use with remote mounted valves.

Tandem center control valves should not be used with

Figure 3 - Control Valve Mounting Station

and Cover Plate (D03 Manifold Shown)

5.3 Hydraulic Reservoir

The pump is shipped without oil. Reservoir must be ﬁ lled with oil before pump is operated.

Use only a high quality ISO 32 grade hydraulic oil recommended.

NOTICE

• Failure to use the correct oil type (high-quality ISO 32 hydraulic oil) may result in damage to pump hydraulic components and will void the product warranty.

• Be sure that the oil is clean. The oil cleanliness should be maintained to a maximum level of 18/16/13 per the ISO 4406 standard. If the oil develops a milky, cloudy or dark appearance, it should be changed immediately.

• To avoid overﬁ lling and possible equipment damage, add oil to the pump reservoir only after all connected hydraulic devices are de-energized and system pressure is completely relieved.

Add oil as described in the following steps:

1. Be certain that the air shut-o valve is in the OFF position

2. Verify that the pump hydraulic pressure gauge and pump

air pressure gauge both read zero (0) psi/bar.

3. Be sure that all connected hydraulic devices are fully de-

pressurized.

4. Loosen the vent screw one full turn to provide reservoir

venting.

5. Loosen and remove the oil ﬁ ll plug. See Figure 4.

6. Slowly pour oil through the oil ﬁ ll port while watching the

level in the reservoir sight gauge. Stop pouring when the reservoir is 1/2 to 3/4 full. DO NOT OVERFILL. Refer to Section 5.4 for additional information.

7. Reinstall the oil ﬁ ll plug after adding oil. Tighten oil ﬁ ll plug

snug tight.

Page 7

Refer to Section 4.2 for port type and thread size.

Figure 4 - Oil Fill Plug

5.4 Oil Level

The oil level sight gauge is located on the left-hand side of the pump,

The reservoir should be 1/2 to 3/4 full with all cylinders or other hydraulic actuators fully retracted. See Figure 5.

Never allow the oil level to rise above the top (high) line or fall below the bottom (low) line.

NOTICE

OFF position and the hydraulic system fully depressurized. Be certain that all hydraulic actuators are fully retracted. Failure to observe this instruction may result in the reservoir becoming overﬁ lled.

Always check oil level with the air on-o control in the

Oil Level

Figure 6 - Hydraulic Connections

5.6 Air Requirements

CAUTION

ensure that the air on-o control is in the OFF position. Failure to follow these directions may result in unintended pump startup when air supply hose is connected.

To ensure optimum performance, the air source must be capable of providing a constant supply of air at the required pressure and ﬂ ow rate for your pump model. Refer to Table 4.1 for additional information.

NOTICE

bar] static for MAP30 Series models. Supply air pressure should not exceed 120 psi [8.2 bar] static for MAP07 and MAP15 Series models.

Before connecting the air supply hose,

Supply air pressure should not exceed 110 psi [7.5

Air Inlet

Air coupler

1/4" NPT

(user-supplied)

Figure 5 - Oil Level Sight Gauge

Add oil if the oil level drops below 1/2 full. A small amount of additional oil may need to be added to the reservoir after the pump has been operated for the ﬁ rst time.

5.5 Hydraulic Hose Connections

The advance and retract ports are located on the front of the hydraulic manifold. See Figure 6. Note that the top ports are labeled “B” and the bottom ports are labeled “A”.

Port type and thread size will vary, depending on pump model. Refer to Section 4.2 of this manual for additional information.

All hoses, ﬁ ttings and other hydraulic components in the circuit must be rated at or above the pump maximum working pressure. Refer to sections 4.1 and 6.2 of this manual for additional maximum pressure information.

Figure 7 - Pump Air Inlet

Use only dry and ﬁ ltered compressed air. Use of a water separator is strongly recommended. Pump internal components are selflubricating. Lubricated air is permitted but NOT required.

The pump air inlet connection is a 1/4" NPT ﬁ tting. See Figure 7.

A suitable male air coupler (user supplied) must be installed between the pump air inlet connection and the air supply line or hose. Use PTFE sealing tape (or other suitable pipe sealant) on the threads and torque to 7.4-11.0 ft-lb [10-15 Nm].

To ensure su cient air ﬂ ow, the inside diameter of the air supply hose or line must be not less than 0.39 inch [10 mm].

Page 8

5.7 Venting

A vent screw is located on the pump reservoir. Before using the pump, loosen the vent screw one full turn to open the vent. See Figure 8.

NOTICE

Reservoir must be vented during pump operation. Failure to open the vent may result in cavitation and damage to pump components.

The vent should also be opened before adding oil to the reservoir. This will allow the oil to ﬂ ow more easily into the tank.

The vent should be fully closed during sustained periods of inactivity or whenever the pump is stored. When closing the vent, tighten the vent screw snug tight, so that the underside of the screw head only slightly compresses the O-ring seat.

Vent Screw

Figure 8 - Vent Screw

5.8 Air On-O Control

The pump air on-o control operates as follows:

all positions several times to relieve any residual pressure.

Figure 9 - Air On-Off Control

5.9 Air Pressure Adjustment

Adjustment of the pump air pressure setting results in a corresponding change to the pump hydraulic pressure setting.

Adjust the pressure setting as described in the following steps:

1. Move the air on-o control to the OFF position.

2. Connect the air supply hose to the pump air inlet connection.

3. Pull up the air pressure adjustment knob. See Figure 10.

4. Turn the air pressure adjustment knob slowly counterclockwise until the pump air pressure gauge indicates about 43.5 psi [3 bar].

5. While watching the pump air pressure gauge, slowly rotate the air pressure adjustment knob clockwise until the gauge indicates the air pressure setting that corresponds with the hydraulic pressure setting required for your application.

NOTICE

on pump model. Refer to the ratios listed in the table in Section

4.1 and to the pressure-ﬂ ow graphs in Section 4.5.

6. To prevent unexpected actuator operation from occurring in

The hydraulic-to-air pressure ratio varies, depending

the next step, be sure that all control valves are in the neutral position.

ON position:

• Air from the plant air supply is directed to the pump pneumatic circuit, activating the pump element. Hydraulic pressure will start building immediately, and will be indicated on the pump hydraulic pressure gauge.

• Pump will stop automatically when the user-adjustable pressure setting is reached. Refer to Section 6.1 for additional details.

NOTICE

The user-adjustable pressure setting must be adjusted before the pump is placed into operation. Refer to directions in Section 5.9.

OFF position:

• Air from the plant air supply to the pump pneumatic circuit is blocked (shut-o ).

• Some residual air pressure may still be present in the pump pneumatic circuit.

WARNING

Air downstream of the air on-o control is NOT vented when the OFF position is selected. Residual air pressure may be present downstream of the control. Movement of hydraulic actuators could occur when control valves are shifted, even when the air on-o control is in the OFF position.

To prevent possible injury, stay clear of hydraulic actuators until all pressure is completely relieved. With the air on-o control in the OFF position, shift the control valve(s) through

LOCKED

ADJUSTMENT

KNOB

UNLOCKED

Air Pressure Gauge

Figure 10 - Air Pressure Adjustment Knob

and Pressure Gauge

7. Move the pump air on-o control to the ON position.

8. Check the pump hydraulic pressure gauge. If necessary, readjust the air pressure up or down as required, until the corresponding hydraulic pressure setting is correct for your application.

Page 9

WARNING

hydraulic pressure gauge must not exceed the maximum rating of the lowest rated hydraulic component in the circuit. Failure to observe this instruction may result in catastrophic failure, high pressure oil leakage and/or skin penetration. Serious personal injury or death could result.

9. After conﬁ rming the proper setting, press down on the air

adjustment knob to lock the setting.

The pressure reading shown on the pump

5.10 Air Removal

Trapped air must be removed from the hydraulic cylinder(s) and hoses before the pump is placed into operation.

1. Move the air on-o control to the ON position.

2. Under no load, repeatedly cycle the cylinders (or other

hydraulic actuators) from the fully extended to fully retracted position until operation is smooth. Repeat this procedure for each valve station.

Smooth operation indicates that air has successfully been

removed from the system.

3. Move the air on-o control to the OFF position.

4. Check the oil level in the pump hydraulic reservoir. If oil level

has dropped, add additional oil to the reservoir as required.

NOTICE

requirements and reservoir ﬁ lling instructions.

5. Check the air pressure setting after performing air removal

Refer to Section 5.3 of this manual for hydraulic oil

procedures. The air pressure setting (and the corresponding hydraulic pressure setting) may drop slightly after the pump has been operated for the ﬁ rst time. If readjustment is required, refer to the instructions in Section 5.9.

6.0 OPERATION

Speciﬁ c pump operation procedures will vary, depending on control valve type and conﬁ guration, workholding devices used and other factors. For detailed operating instructions and related information, refer to the instruction sheet included with your hydraulic valve(s), cylinder(s) or other actuator(s). Refer to Section 6.1 for a general overview of pump operation. Also follow the additional instructions and precautions contained in sections

6.2 and 6.3 of this manual.

6.1 Overview of Operation

Typical operation - with standard closed center or ﬂ oat center control valves (pressure holding type):

• The pump will start immediately if the air on-o control is

moved to the ON position while the control valve is in the neutral position. The pump will stop automatically (and remain idle) when pressure reaches the user-adjustable pressure setting.

• If the pump is idle, and the control valve is moved from the

neutral position to either the advance or retract position, the pump will start immediately. The pump will stop automatically when pressure reaches the user-adjustable pressure setting.

Typical operation - with spool type closed center or ﬂ oat center control valves (non-sealed type):

• When the air on-o control is in the ON position and the control

valve is in the neutral position: The pump will start and stop as needed to maintain the user-adjusted pressure. This feature helps compensate for the normal internal oil leakage present in a spool type control valve.

• Operation is otherwise the same as described for the standard

(pressure holding type) control valves.

NOTICE

It is mandatory that the operator has a full understanding

of all instructions, safety precautions and applicable safety regulations before operating any high force hydraulic equipment. If any questions or concerns, contact Milwaukee Cylinder customer service representative.

6.2 Maximum Hydraulic Working Pressure

Rated maximum hydraulic working pressure varies, depending on the pump model:

• MAP07 Series: 1920 psi [132 bar].

• MAP15 Series: 2760 psi [190 bar].

• MAP30 Series: 5280 psi [364 bar].

WARNING

Maximum hydraulic system pressure is limited by an internal safety relief valve that is set slightly higher than the pump's maximum rated hydraulic working pressure. Do not attempt to adjust, bypass or alter this valve. It is factory set and is not user-adjustable.

Be certain that all hydraulic hoses, hydraulic cylinders and any other connected hydraulic devices are rated at or above the maximum hydraulic working pressure for your pump model.

Serious personal injury or death could occur if these instructions and precautions are not followed.

6.3 Relieving Pneumatic and Hydraulic Pressure

WARNING

Failure to observe the following instructions and precautions could result in dangerous high pressure oil leakage and possible skin penetration. Death or serious personal injury could result.

Perform the following procedure before disconnecting any hydraulic hoses or lines from either the pump manifold or a connected device, before loosening any hydraulic ﬁ ttings or before servicing the pump or any connected devices:

1. Move the pump air on-off control to the OFF position. See Figure 9.

2. Disconnect the air supply hose from the pump air inlet connection. Be certain that the pump air pressure gauge indicates zero (0) psi/bar. See Figure 10.

3. Cycle the hydraulic control valve(s) to relieve residual pressure in the pump hydraulic system (this will also remove residual pressure in the pump pneumatic system).

Figure 11 - Pump Hydraulic Pressure Gauge

4. Verify that all hydraulic pressure is completely relieved:

- Check that the pump hydraulic pressure gauge indicates zero (0) psi/bar. See Figure 11.

- Verify that other hydraulic pressure gauges in the system (if present) also indicate zero (0) psi/bar.

Page 10

- Be sure that no hydraulic hoses are sti , which may indicate trapped pressure.

5. If any hydraulic pressure remains, cycle the control valve(s) again to relieve pressure. Then, re-check the hydraulic pressure gauge(s) to be sure that no pressure is indicated.

7.0 INSPECTION, MAINTENANCE & STORAGE

• Periodically check the pump for loose hydraulic connections

leaks and obvious problems. Replace any damaged components immediately.

• Monitor the pump oil temperature during operation. Do not

exceed oil temperatures above 150°F [65°C].

• Install dust caps and plugs on all hydraulic couplings after the

hydraulic hoses are disconnected from the pump.

• Keep the pump and all hydraulic components clean.

• Change the hydraulic oil at the recommended interval shown

in Section 8.2 of this manual. Change the oil immediately if dirty, or if contamination is suspected.

• Store the pump in a clean, dry and secure location. Keep the

stored pump and hoses away from heat and direct sunlight.

• If repair parts are required, refer to the Milwaukee Cylinder

website (www.milwaukeecylinder.com) for the repair parts sheet applicable to your pump model.

NOTICE

a qualiﬁ ed hydraulic technician. For repair service, contact Milwaukee Cylinder customer service representative.

Hydraulic equipment must only be serviced by

8.0 ROUTINE MAINTENANCE PROCEDURES

8.1 Preparation

Always perform the following steps before beginning any maintenance or repair procedures contained in Section 8:

1. Disconnect the air supply hose and fully relieve pneumatic and hydraulic pressure. Follow the steps in Section 6.3.

2. Disconnect hydraulic hoses from hydraulic manifold. Install plugs in open ports.

3. Position the pump on a workbench or other substantial work surface.

NOTICE

ﬁ gure does NOT include the weight of the hydraulic oil or the control valves. Actual weight will vary, depending on amount of oil in reservoir and number of control valves installed on manifold.

4. Remove the two screws located on either side of the pump

Pump dry weight is approximately 71 lb [32.2 Kg]. This

shroud. Remove the pump shroud and position it behind the pump on the work surface. Be careful not to damage the ﬂ exible air tubing, which must remain connected. See Figure

12.

Figure 12 - Pump Shroud Removal

(Note: air tubing removed for illustrative purposes)

8.2 Oil Change

Change the hydraulic oil every 12 months. If the oil is dirty or contaminated, change the oil immediately. Refer to the following steps:

1. Fully relieve pressure in the pneumatic and hydraulic circuits. Disconnect hoses. Refer to maintenance preparation procedures in Section 8.1 of this manual. Also refer to pressure relief procedures in section 6.3.

2. Place the pump on a workbench or other substantial work surface. To allow draining in the next step, position the pump so that the side with the oil drain plug is even with the edge of the workbench.

3. Place a suitable container under the pump oil drain plug. The container capacity must be 1.8 gallon [6.8 liter] or larger.

4. Slowly unscrew the oil drain plug and remove it. See Figure

13. Allow the old oil to ﬂ ow into the container.

NOTICE

laws and regulations.

5. Clean and reinstall the oil drain plug.

6. Remove the oil ﬁ ll plug. See Figure 4.

NOTICE

recommended. Refer to Section 5.3 for additional information.

7. Slowly pour new oil through the oil ﬁ ll opening while watching

8. Reinstall the oil ﬁ ll plug.

Dispose of used oil in accordance with all applicable

Use of Enerpac HF hydraulic oil is strongly

the oil sight gauge. Continue until reservoir is 1/2 to 3/4 full. DO NOT OVERFILL.

Page 11

Drain Plug

Figure 13 - Drain Plug

9. Reconnect hoses and test pump operation without load before placing the pump back into service. Cycle the hydraulic cylinders (or other hydraulic actuators) until all air is removed and operation is smooth.

8.3 Suction Strainer Replacement

Two suction strainer ﬁ lters are located inside the pump oil reservoir. Replace these strainers if there is a noticeable drop in oil ﬂ ow or if it is suspected that the oil is dirty or contaminated. Refer to the following steps:

1. Fully relieve pressure in the pneumatic and hydraulic circuits. Disconnect hoses. Remove pump shroud. Refer to maintenance preparation procedures in Section 8.1 of this manual. Also refer to pressure relief procedures in Section

6.3.

2. Place the pump on a workbench or other substantial work surface.

3. Fully drain all oil from the hydraulic reservoir. Refer to the steps in Section 8.2.

NOTICE

changed whenever the suction strainers are replaced.

4. Check that the pump hydraulic pressure gauge indicates

5. Loosen the connectors located on each end of the hydraulic

To ensure cleanliness, the hydraulic oil MUST be

zero (0) psi/bar. Hydraulic pressure must be completely relieved before loosening hydraulic ﬁ ttings in the following step.

manifold. Refer to Figure 14.

Figure 14 - Connectors

(Located on each end of manifold)

Page 12

Figure 15 - Manifold Assembly

6. Remove the bolts and sealing washers securing the hydraulic manifold and cover plate to the hydraulic reservoir. See Figure 15.

NOTICE

Hydraulic manifold and cover plate assembly weighs approximately 20 lb. [9 kg]. Manifold mounted control valves will add additional weight.

7. Carefully lift the manifold and cover plate assembly straight

up until it is removed from the hydraulic reservoir. See Figure

15. Set this assembly aside, in a clean and dry location.

8. Install caps or plugs over all open ﬁ ttings to prevent dirt

entry.

9. Inspect the hydraulic reservoir. Remove any sludge or debris

from the reservoir interior.

10. Unscrew and remove each oil suction strainer. Discard both

used suction strainers. See Figure 16.

Key:

1. Connector

2. Adapter

3. Suction Strainer

Figure 16 - Suction Strainer

11. Install two new oil suction strainers. Be sure that each new suction strainer is oriented as shown in Figure 16. Hydraulic ﬁ ttings must be assembled so that ﬂ at side of suction strainer is parallel with reservoir ﬂ oor. Refer to the pump repair parts sheet for part number.

12. Clean the mating surfaces of the reservoir and the hydraulic manifold cover plate.

13. Check the condition of the reservoir gasket. If the gasket is worn or deteriorated, install a new reservoir gasket. Refer to the pump repair parts sheet for part number.

14. Remove caps and plugs installed in step 8.

15. Carefully lift the manifold and cover plate assembly and position it directly over the hydraulic reservoir opening. Note the locating tabs on either side of the reservoir ﬂ ange.

16. Slowly lower the assembly until the manifold cover plate is supported by the hydraulic reservoir ﬂ ange. Align bolt holes.

17. Apply PTFE pipe thread sealing tape to the threads of the two hydraulic tubes. Engage threads of connectors and hydraulic tubes. Tighten each connector until ﬁ nger tight. DO NOT ﬁ nal tighten at this time.

18. Secure the manifold cover plate to the hydraulic reservoir with twelve bolts and sealing washers. Torque each bolt to 20-22 in-lbs [2.26-2.49 Nm].

19. Tighten both connectors an additional 2-3 full turns beyond ﬁ nger tight.

20. Reﬁ ll the hydraulic reservoir. Refer to the steps in Section

8.2 of this manual.

21. Reconnect hoses and test pump operation without load before placing the pump back into service. Cycle the hydraulic cylinders (or other hydraulic actuators) until all air is removed and operation is smooth.

8.4 Air Filter/Regulator

The air ﬁ lter/regulator contains a removable ﬁ lter bowl and cleanable air ﬁ lter. Periodically check the ﬁ lter bowl for accumulated water and clean the ﬁ lter. Refer to the following procedure:

6.3.

Page 13

2. Locate the air ﬁ lter/regulator. It is mounted inside the pump shroud.

3. Grasp the ﬁ lter bowl and depress the release button. Pull straight down and remove the ﬁ lter bowl from the air regulator. See Figure 17.

4. Drain any accumulated water from the ﬁ lter bowl. Remove any dirt or debris. Wipe the ﬁ lter bowl clean.

5. A ﬁ lter element is located inside the air regulator housing. Using a clean rag, wipe o any loose dirt or dust from the ﬁ lter element.

NOTICE

damaged, replace the entire ﬁ lter/regulator. Replacement parts are not available from Milwaukee Cylinder for this device. Order complete ﬁ lter/regulator unit. Refer to pump repair parts sheet for ﬁ lter/regulator part number.

6. Reinstall the ﬁ lter bowl in the air regulator. Be sure it locks

7. Reconnect the air supply hose to the pump air inlet

If the ﬁ lter element is very dirty, or if the ﬁ lter bowl is

into place.

connection. Test pump operation without load before placing the pump back into service.

the tapped center hole of the end cap.

WARNING

may be present under the end cap. End cap may eject suddenly as it is being removed, even if the pump air pressure gauge indicates zero (0) psi/bar. To prevent possible eye injury, wear safety goggles during disassembly procedures.

3. Using a snap ring pliers, remove the snap ring.

4. Using a suitable needle nose pliers, grasp the head of the

M5 bolt. Pull straight up and remove the end cap from the bore of the shuttle valve assembly.

5. Remove the M5 bolt from the end cap and reinstall it in the

tapped center hole of the piston.

6. Using a suitable needle nose pliers, grasp the head of the

M5 bolt. Pull straight up and remove the piston from the bore of the shuttle valve assembly.

8.5.2 Inspection

1. Using a clean, lint free rag, remove the old grease lubricant

from piston, end cap, and from the valve assembly bore.

2. Inspect piston and end-cap for excessive wear, nicks,

scratches, corrosion or other problems.

A small amount of pressurized trapped air

Air Regulator

Filter Bowl

Figure 17 - Air Regulator and Filter Bowl

8.5 Air Shuttle Valve Routine Maintenance

The pump air shuttle valve is located on the right-hand side of the pump element (when the pump is viewed from the rear). The valve end cap and piston must be inspected, cleaned and lubricated at the recommended time interval to ensure optimum pump operation.

NOTICE

least every 100,000 cycles.

Refer to Figure 18 during the following procedures.

8.5.1 Disassembly

1. Fully relieve pressure in the pneumatic and hydraulic

2. To aid end cap removal, install an M5 bolt (user supplied) in

Disassemble and inspect the pump air shuttle valve at

circuits. Disconnect hoses. Remove pump shroud. Refer to maintenance preparation procedures in Section 8.1 of this manual. Also refer to pressure relief procedures in Section

6.3.

1. Snap Ring

2. End Cap

3. Piston

4. Housing

M5 Bolt

(user-supplied)

Figure 18 - Air Shuttle Valve Components

3. Check the condition of all piston seals. Replace entire piston

assembly if seals are worn or damaged.

NOTICE

entire air shuttle valve assembly. Individual components and seals are not sold separately.

8.5.3 Reassembly

1. Using a small brush, lubricate the O-rings and seals on the

If obvious wear or damage is indicated, replace the

Page 14

piston with lithium grease.

2. If removed, re-install the M5 bolt in the tapped center hole of the piston.

3. Align the piston with the bore opening and carefully reinstall it in the bore.

4. Using a suitable needle nose pliers, apply ﬁ rm pressure to the head of the M5 bolt until the piston has bottomed out in the bore of the housing. Then, unscrew and remove the M5 bolt.

5. Align the end cap with the bore opening and position it in the bore.

6. Using a suitable needle nose pliers, apply ﬁ rm pressure to the end cap until it has bottomed-out, and is located just below the snap ring groove.

7. Using a snap ring pliers, reinstall the snap ring.

8.6 Pump Element Air Switch Maintenance

The pump element contains two air switches, one located on each side of the pump element. The air switches must be inspected, cleaned and lubricated at the recommended time interval to ensure optimum pump performance.

NOTICE

least every 100,000 cycles.

Disassemble and inspect the pump air switches at

switch. Refer to Figures 19 and 20.

8.6.1 Disassembly

6.3.

2. Using an adjustable wrench, loosen and remove the air switch cap nut.

3. Using a right-angle needle nose pliers, grasp the end of the air switch piston and carefully pull it straight out of the air switch bore.

4. If it was not removed with the piston, remove the coil spring.

8.6.2 Inspection

1. Using a clean, lint free rag, remove old grease lubricant from the air switch bore, the piston and the coil spring.

2. Inspect piston for obvious wear, nicks, scratches, corrosion or other problems. Recondition or replace piston as required.

3. Check the condition of both piston seals. Replace entire piston assembly if seals are worn or damaged.

NOTICE

entire air switch assembly. Individual components and seals are not sold separately.

4. Inspect the coil spring. Replace if broken, bent or obviously

8.6.3 Reassembly

1. Using a small brush, lubricate the piston surface, O-rings

2. Place the coil spring around the piston.

3. Carefully place the piston and coil spring into the air switch

4. Engage the threads on the cap nut with the threads in the air

If obvious wear or damage is indicated, replace the

worn. Refer to pump repair parts list for part number.

and seals with lithium grease.

bore.

switch bore. Using a wrench, tighten the end cap snug tight.

Figure 19 - Air Switches

(viewed with shroud removed)

Key:

1. Cap Nut

2. Coil Spring

3. Piston

Figure 20 - Air Switch - Exploded View

Always perform maintenance procedures for BOTH air switches. Follow the instructions in sections 8.6.1 through 8.6.3 for each air

8.7 Air Exhaust Mu er

The pump air shuttle valve contains a mu er assembly. The mu er felt must be replaced at the recommended time interval to ensure optimum pump performance.

NOTICE

Replace the air exhaust mu er felt as described in the following steps:

1. Fully relieve pressure in the pneumatic and hydraulic

2. Loosen and remove the four screws securing the cover to

3. Remove the cover. Remove and discard the old mu er felt.

NOTICE

Cylinder, but is available from many pneumatic maintenance supply distributors.

4. Place the new mu er felt inside the cover.

5. Position the cover plate against the air shuttle valve and

Replace the mu er felt at least every 100,000 cycles.

circuits. Disconnect hoses. Remove pump shroud. Refer to maintenance preparation procedures in Section 8.1 of this manual. Also refer to pressure relief procedures in Section

6.3.

the air shuttle valve. See Figure 21.

Exhaust mu er felt is not purchasable from Milwaukee

secure it with four screws.

Page 15

9.0 TROUBLESHOOTING

Refer to the troubleshooting guide when diagnosing pump operational problems. Please note that the troubleshooting guide

is not all-inclusive, and should be considered only as an aid to help diagnose the most common possible problems.

For repair service, contact Milwaukee Cylinder customer service representative. As required, also refer to the troubleshooting information provided with your hydraulic control valves and other system components.

Key:

1. Screw

2. Cover

3. Mu er Felt

4. Air Shuttle Valve

Figure 21 - Air Exhaust Muffler

TROUBLESHOOTING GUIDE

Problem Possible Cause Action

Pump does not cycle. No air pressure at supply. Check air supply.

Pump air-shuto valve closed. Open pump air-shuto valve.

Pump air pressure regulator set too low. Check pressure regulator setting.

Pump air exhaust mu er dirty. Clean or replace the mu er felt. Refer to Section 8.7

Pump air shuttle valve needs cleaning and lubrication.

Pump air motor worn or damaged. Contact Milwaukee Cylinder customer service

Pump element jammed. Contact Milwaukee Cylinder customer service

Pump fails to build hydraulic pressure or builds less than desired pressure.

Pump Noise. Low air pressure or volume at air supply. Check air supply.

Low air pressure or volume at air supply. Check air supply.

Pump air pressure regulator set too low. Check regulator setting.

Pump air exhaust mu er dirty. Clean or replace the mu er felt. Refer to Section 8.7

Control valve returning oil to reservoir. Change position of control valve.

Low oil level in reservoir. Check oil level. Add oil as required.

Pump suction strainer elements dirty. Replace pump suction strainer elements. Refer to

Oil leakage at hydraulic hoses, ﬁ ttings or connected devices.

Internal leakage in control valve or valve manifold. Repair or replace components as required.

Internal leakage in pump element. Pump element worn or damaged.

Pump air pressure regulator set too low. Check regulator setting. Refer to Section 5.9 of this

Pump air exhaust mu er dirty. Clean or replace the mu er felt. Refer to Section 8.7

(continued on next page)

of this manual.

Refer to procedure in Section 8.5 of this manual.

representative.

of this manual.

Section 8.3 of this manual.

Replace leaking components as required.

Contact Milwaukee Cylinder customer service representative.

manual.

of this manual.

Page 16

TROUBLESHOOTING GUIDE (continued)

Problem Possible Cause Action

Oil leakage Loose connections. Tighten loose connections. Replace any worn or

Worn or damaged components. Repair or replace components as required.

Jerky or erratic pump operation. Low air pressure or volume at plant air supply. Check plant air supply.

Air in hydraulic lines. Remove air as described in Section 5.10 of this

Hydraulic oil dirty. Change hydraulic oil. Use Enerpac HF oil. Refer to

Low oil level in reservoir. Check oil level. Add oil as required. Refer to sections

Pump suction strainer elements dirty. Replace pump suction strainer elements. Refer to

Internal leakage in pump element. Pump element worn or damaged.

Excessive moisture in pump exhaust.

Air leakage. Loose air system connections. Tighten connections as required.

Excessive water and/or lubricant in supply air. Reduce moisture in air. Install water separator.

Pump air ﬁ lter bowl needs draining. Check bowl for water. Drain as required. Refer to

Pump air ﬁ lter dirty. Clean air ﬁ lter element. Refer to Section 8.4 of this

Internal leakage in pump element. Pump element damaged or worn.

damaged connectors.

manual.

Section 8.2 of this manual.

5.3 and 5.4 of this manual.

Section 8.3 of this manual.

Contact Milwaukee Cylinder customer service representative.

Note: Pump components are self-lubricating. Lubricated air is permitted, but not required.

Section 8.4 of this manual.

manual.

Contact Milwaukee Cylinder customer service representative.

Worn or damaged air system components. Repair or replace components as required.

Cylinder drift. External system leak. Repair or replace leaking components as required.

Internal leak in system component. Repair or replace leaking components as required.

Low oil ﬂ ow rate. Reservoir not vented. Open vent screw on reservoir. Refer to Section 5.7 of

Pump air ﬁ lter bowl needs draining. Check bowl for water. Drain as required. Refer to

Pump air ﬁ lter dirty. Clean air ﬁ lter element. Refer to Section 8.4 of this

Internal leakage in pump element. Pump element worn or damaged.

Low air pressure or volume at air supply. Check air supply.

Pump air pressure regulator set too low. Check regulator setting. Refer to Section 5.9 of this

Pump suction strainer elements dirty. Replace pump suction strainer elements. Refer to

Cylinder will not return. Return ﬂ ow blocked or restricted. Check system for blockages and make repairs

Control valve malfunction. Repair or replace control valve as required.

this manual.

Section 8.4 of this manual.

manual.

Contact Milwaukee Cylinder customer service representative.

manual.

Section 8.3 of this manual.

as required. Be sure that all couplers are fully connected.

Page 17

Notes:

Page 18

Notes:

Page 19

Notes:

Page 20

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