Milwaukee Cylinder DuroTech, MAP07, MAP15, MAP30 Instructions Manual

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-

1

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.

2

2

1

9

8

7

B

A

6

Key:

1. Hyd. Pressure Gauge

5

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

B

B

A

B

A

A

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

3

4

11

10

12

16

17

15

13

14

Figure 1 - Major Features and Components

3

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

1)

Max. Hyd.

Pressure

@100 psi Air

[6.9 bar]

2)

Hyd. Safety
Relief Valve

Setting

Pressure

Ratio

Hydraulic

to Air

Max. Hydraulic

Flow

@100 psi Air

[6.9 bar]

3

/min l /min psi bar scfm m³/min

2)

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

3

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

4

4.4 Pump Dimensions

u

Item inch mm

A 8.9 226

ø 0.31

B

x

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

B

A

C

D

BABABAB

A

E

F

G

4.5 Performance Curves (hydraulic pressure vs. fl ow)

Imperial

900

800

700

600

/min) X

3

500

400

300

Oil flow (in

200

100

0

0 200 400 600 800 1000 1200 1400 1600 1800

Hydraulic Pressure (psi)

60 psi
80 psi
100 psi

Air pressure

X

700

600

500

/min) X

400

3

300

200

Oil flow (in

100

0

0 500 1000 1500 2000 2500 3000

Hydraulic Pressure (psi)

60 psi
80 psi
100 psi

Air pressure

X

MAP07 Series MAP15 Series MAP30 Series

350

300

250

/min) X

200

3

150

100

Oil flow (in

50

0

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

0 14 28 41 55 69 83 97 110 124

Hydraulic Pressure (bar)

4.1 bar

5.5 bar

6.9 bar

Air pressure

X

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

X

5.7

4.9

4.1

3.3

2.5

1.6

Oil flow (l/min) X

0.8

0

0 69 138 207 276 345 414

Hydraulic Pressure (bar)

WAP07-Hydra

60 psi
80 psi
100 psi

Air pressure

X

4.1 bar

5.5 bar

6.9 bar

Air pressure

X

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.

5

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.

6