HIGH PRESSURETECHNOLOGYHYDRAULICSPNEUMATICSTESTINGEQUIPMENT

MAXIMATOR GmbH

Description and function of MAXIMATOR power packs
MAXIMATOR power packs for oil, water or aggressive

On request, the tanks can be provided with carrying

media are complete hydraulic units ready for connection

handles or on wheels (to be recommended for all G-typewhich are provided for generating operating pressures up

pumps as well as for tank capacities from 30 l).

to 5,500 bar.The hydraulic systems can be used for all
kinds of testing and clamping or for other functions

On the high-pressure side, therequiring a determined pressure.

power pack will be equipped with apressure relief valve (expansion

The pressure will be generated by means of a pneumatical-

valve) as well as with a manifold

ly operated MAXIMATOR pump. The pump will be con-block with one or several pressurenected to the existing industrial compressed-air ductwork

outlets for connecting the test pieces

system. For generating the pressure, an electric connection(which can be shut off separately or

will not be necessary.

completely on request).

MAXIMATOR power packs can be equipped with all

For indicating and monitoring the operating pressure,

MAXIMATOR pumps. Restrictions result only fromliquid-damped pressure gauges of the accuracy class 1.0

determined structural dimensions as well as from the flowor 1.6 (higher accuracies are possible on demand) can berates of the pumps being necessary for thedelivered in different sizes for pressures up to 7,000 bar.

respective function.
With the above specified scope of supply, the MAXIMATOR
power pack is ready for connection. For operating the

For the simple commissioning

hydraulic unit, only the drive air piping has to be

and unproblematic application,connected and the tank has to be filled with the provided

MAXIMATOR power packs will

operating liquid.

be equipped with all requiredcomponents. Part of them is an

MAXIMATOR offers an extensive volume of accessories for

air control unit with combined

all cases of application. Part of them are pressure switches,filter and water seperator, afloat valves and pneumatically or electrically operatedpressure-regulating valve, a pressure control gauge as well
as a manual shut-off valve for stopping off the drive airpressure.

directional valves for actuating cylinders. Connecting
adaptors, quick couplings, pressure filters, high-pressure
hoses as well as shut-off valves and control valves areavailable too.

For all applications within the range of the oil hydraulic,the pumps will be mounted in the oil tank in a compact andWe design the MAXIMATOR power packs according tospace saving manner. In case of operation with water oryour requirements. Our sales engineers in the engineeringwith aggressive media, the pump will be mounted on thedepartments as well as our co-workers in the Works Zorge

tank. According to standard, there can be selected among

are pleased to give you expert advice and will recommend

tank capacities from 6.5 l to 70 l. Larger-sized tanks are

you the respective power pack being suitable for your spe-

available on demand.

cial case of application.

2

MAXIMATOR ® - Complete Solutions in the High-Pressure TechniqueApplications for MAXIMATOR power packs
The movable and portable MAXIMATOR hydraulic power

the quick return. The hydraulic units have also proved to be

packs can be used wherever hydraulic pressures are

an outstanding solution for isostatic pressing procedures.

required. They are to be found for example in the steel
construction, boiler construction, tank construction andreactor construction as well as in yards, smelting plants,
machine factories and locksmith's shops. For years they
have proved themselves in inspection and acceptanceFor realizing regular pressure tests (TÜV) at pressure
vessels, MAXIMATOR offers the complete solution withregard to the pressure generation. These power packs will
always be set up upon customer's request.

processes as well as in the hydraulic working and

The required hydraulic pressure will be generated byclamping systems.

means of air-lift pump. In this connection, the hydraulic

The power packs are also provided for actuating hydraulicpressure corresponds to the set air pressure multiplied bypunches and punch systems. Among others they will be

the transmission ratio of the pump. When the applianceused in aircraft yards for lifting aircrafts, for clamping

reaches the pre-set pressure, it stops automatically andlarge-sized devices, for checking pressure vessels and pres-maintains the pressure until arising a pressure drop caused

sure systems.

through leakage or the like. The appliance starts automatically and functions again until having reached the pre-set
pressure.
All the controlling and regulating processes are ofunsurpassed simplicity because of the compressed-air
drive. So, the complete appliance is very robust,
operationally reliable and insensitive to hardest operatingstresses. The power pack will not be damaged throughmoist rooms, dust or higher temperatures. The
MAXIMATOR hydraulic units are explosion-proof because
no electric energy is required.

In the tool hydraulic, MAXIMATOR units will be used forpressure oil junctions as well for mounting and pulling-off
large-sized toothed gears.
Furthermore, the systems will be used in hydraulic presses,
among others also when high pressure must be maintained
for a long time, such as in case of tire and vulcanizingpresses as well as for presses overload protections. For
such purposes, the hydraulic unit can be delivered withreversing devices permitting an one-sided or also twosided admission to the press. Direct admission ofcompressed air to the return side enables a connection for

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

MAXIMATOR ® - Complete Solutions in the High-Pressure Technique3

Packaged Pump Systems for Outlet
Pressures up to 5,500 bar
10

1

7

2

6

3

9

4

8

5

11
Note: MAXIMATOR pumps MO and S
series are integrated in the tank.
All other pump series will be mounted on
top of the tank.

Components in Modular Design:

1
2

Pump model
MO, S for oil service up to maximum 1,000 bar; M, G for
oil and water service up to maximum 5,500 bar; MSF,
GSF for special liquids to maximum 1,450 bar

7

Air control unit, comprising combined filter pressure
regulator, control pressure gauge and shut-off valve
C1
for M series
C1.5 for S series
C2
for G series

83

Air safety valveSV
mounted in the air line

4

Tank sizes
6.5 liter
13 liter
30 liter
70 literStandard of aluminium, stainless steel on request

5

Mobility of the packaged pump systemFmoveableT
portableKjack ring

6

Relief valveEVwith return line to the tank

1

9

Pressure gauge
Pressure range / Diameter of the housing(cl. 1.6/1.0/0.6, glycerine damped)
Operating liquidO
Oil (tank of aluminium, components galvanized)
W
Water (tank of aluminium, components of SS)
VA
Stainless steel (tank of 1.4571 or 1.4305)
Manifold block with pressure outlet(s)A11 pressure outlet to
A6
6 pressure outlets, depending on tank size
V
Option: Shut-off valve for pressure outlet(AV1-AV6)
Hand lever
only available for M22 to M189, single acting,single stage

10 H

options:
11 Other
SCHW Float valve for automatic filling of the tank, i. e.
from the water line
SCHL HP hose, model SK
ZR
Additional return connection
Specials on request

2

3

4

Coding example: M 189-01 / C1 / SV / 13 /

5

6

7

8

9 10 11F / EV / 0-1600 (160) / W / A2 / H / SCHL

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

4

MAXIMATOR ® - Complete Solutions in the High-Pressure Technique1 : 591

1.9

GX 35
GX 60
GX 100

1 : 36
1 : 66
1 : 117

180
65
36

5.02

630
1050

3.21
1.81

G 150 D1 : 151

7.6

1450

2.10

GSF 150 L 1 : 151

6.6

1450

1.36

S 15 DS 25 DS 35 DS 60 DS 100 DS 150 D1 : 16
1 : 24
1 : 30
1 : 601 : 107
1 : 155

57.0
39.0
25.0
16.0
9.0
6.2

1.16
0.66

0.65
0.51

G300-2L
G400-2L

1 : 628
1 : 796

3.2
2.5

4500
5500

0.56
0.44

4500

0.39

G500-2L

1 : 1038

1.4

5500

0.23

360
600
1000

24.50
23.00
9.00

Typ
e

Pre
ss

Dis
pla
cem
ent

Ou
tlet

Flo
w

Typ
e

Pre
ss

Dis
pla
cem
ent

Ou
tlet

Flo
wl
/m
in *
***

MO 4
MO 8
MO 12
MO 22
MO 37
MO 72
MO 111
MO 1891: 4
1: 9
1 : 14
1 : 29
1 : 47
1 : 881 : 133
1 : 225

30.5
14.7
9.4
4.6
2.8
1.5
1.0
0.6

40
90
140
290
470
880
1000
1000

14.80
7.07
4.55
2.22
1.36
0.72
0.48
0.28

MO 22DMO 37DMO 72D
MO111D
MO189D1 : 28
1 : 46
1 : 86
1 : 130
1 : 220

9.2
5.6
3.0
2.0
1.2

280
460
860
1000
1000

3.91
2.35
1.24
0.82
0.49

1 : 28
1 : 46
1 : 86
1 : 130
1 : 220

9.2
5.6
3.0
2.0
1.2

3.91
2.35
1.24
0.82
0.49

MSF 4LMSF 8LMSF 12L
MSF 22L
MSF 37LMSF 72L
MSF111L

1: 4
1: 9
1 : 14
1 : 28
1 : 46
1 : 86
1 : 130

30.5
14.7
9.4
4.6
2.8
1.5
1.0

40
90
140
280
460
860
1000

14.81
7.07
4.55
2.22
1.36
0.48
0.28

ure
ma
x*
**

**
ure
rat
io

***
l/m
in *

280
460
860
1300
2200

pre
ss

**

M 22D
M 37D
M 72D
M 111DM 189D

vol
um
ec
m3
*

0.35
0.21
0.24
0.14

17.56
12.00
7.58
4.80
2.68
1.85

Dis
pla
cem
ent
vol
um
ec
m3
Ou
*
tlet
pre
ssu
re
ma
x*
**
Flo
wl
/m
in *
***

2500
4000
2500
4000

160
240
300
600
1000
1000

Pre
ssu
re
rat
io

1.0
0.6
1.0
0.6

Typ
e

Dis
pla
cem
ent
vol
um
ec
m3
Ou
*
tlet
pre
ssu
re
ma
x*
**
Flo
wl
/m
in *
***

1 : 266
1 : 450
1 : 399
1 : 675**

M111-2L
M189-2L
M111-3L
M189-3L

Pre
ssu
re
rat
io *
*

Typ
e

9.38
6.72
4.31
2.75
1.55
1.08
0.40

pre
ssu
re
ma
x*

vol
um
ec
m3
*

ure
rat
io

**

Typ
e

**

M 4L
M 8L
M 12L
M 22L
M 37L
M 72L
M 111 LM 189LType

MAXIMATOR standard pump
S series

S 15
S 25
S 35
S 60
S 100
S 150
S 350

MAXIMATOR mini pump
M series

Dis
pla
cem
ent
vol
um
ec
m3
Ou
*
tlet
pre
ssu
re
ma
x*
**
Flo
wl
/m
in *
***

2900
4500

Dis
pla
cem
ent
vol
um
ec
m3
Ou
*
tlet
pre
ssu
re
ma
x*
**
Flo
wl
/m
in *
***

6.6
3.8

Pre
ssu
re
rat
io *
*

1 : 300
1 : 530

Pre
ssu
re
rat
io *
*

G150-2L
G250-2L

***

400

15.7
8.8

1.36
0.77

14.81
7.07
4.55
2.22
1.36
0.72
0.48
0.28

**

GSF 35 L 1 : 40
GSF 60 L 1 : 63
GSF 100 L 1 : 113

24.5

5.04
2.78

G100-2L

40
90
140
280
460
860
1300
2200

ure
ma
x*

7.74

630
1050

pre
ss

400

31.4
17.6

2.70
1.55

30.5
14.7
9.4
4.6
2.8
1.5
1.0
0.6

vol
um
ec
m3
*

29.0

1 : 63
1 : 113

4.30

1260
2100

170
250
390
610
1000
1000
3000

**

1 : 40

800

15.4
8.8

1: 4
1: 9
1 : 14
1 : 28
1 : 46
1 : 86
1 : 130
1 : 220

ure
ma
x*
**

G 35 D
G 60 DG 100 D

24.5

pre
ss

18.53
12.86
7.24

80

28.3
19.6
12.6
8.0
4.5
3.1
1.3

vol
um
ec
m3
*

110
160
280

pre
ss

90.0
62.0
35.3

1 : 126
1 : 226

1 : 17
1 : 25
1 : 39
1 : 61
1 : 108
1 : 156
1 : 370

**

ure
ma
x*
**

um
ec
m3
*
vol

Flo
wl
/m
in *

G 500L

Ou
tlet

3140
3900

Dis
pla
cem
ent

3.2
2.5

GSF 10 L 1 : 11
GSF 15 L 1 : 16
GSF 25 L 1 : 28

Dis
pla
cem
ent
vol
um
ec
m3
Ou
*
tlet
pre
ssu
re
ma
x*
**
Flo
wl
/m
in *
***

1 : 314
1 : 398

28.85
19.84
11.34

ure
rat
io

1450
2650

100
150
270

**

6.6
3.8

180.0
124.0
70.6

Pre
ss

1 : 151
1 : 265

1 : 101 : 15
1 : 27

Pre
ssu
re
rat
io

G 150LG 250LG 300LG 400LG 10 DG 15 D
G 25 DType

G 35-2L
G 60-2L

1:

3.21
1.81

15.89
11.02
6.19

Typ
e

5.02

630
1050

Flo
wl
/m
in *
***

400

15.4
8.8

Ou
tlet

24.5

1 : 63
1 : 113

Dis
pla
cem
ent

1 : 40

220
320
560

Dis
pla
cem
ent
vol
um
ec
m3
Ou
*
tlet
pre
ssu
re
ma
x*
**
Flo
wl
/m
in *
***

G 35L
G 60L
G 100L

90.0
62.0
35.3

ure
rat
io

22
32
56

Pre
ss

1:
1:
1:

Pre
ssu
re
rat
io

G 10-2L
G 15-2L
G 25-2L

Typ
e

18.53
12.86
7.24

Typ
e

110
160
280

Flo
wl
/m
in *
***

Pre
ss

90.0
62.0
35.3

Single acting,single air drive headfor special liquids

Ou
tlet

Typ
e

1 : 11
1 : 16
1 : 28

ace
me
nt

Flo
w

G 10L
G 15L
G 25L

Double acting,single air drive head

Dis
pl

Ou
tl e t

ure
rat
io

l/m
in *
***

**

ure
ma
x*
**

Dis
pl

pre
ss

vol

Pre
ss

ace
me
nt

Typ
e

ure
rat
io

Single acting, double or
triple air drive head

MAXIMATOR mini pump
MO series

MAXIMATOR large pump G series

**

um
ec
m3
*

Single acting,single air drive head

* Displacement volume / Double stroke – calculated** Pressure ratio – Area lp-piston/hp-piston - calculated*** Static Outlet pressure at an air drive of 10 bar – calculated
resp. maximum permitted outlet pressure / Conversion bar : psi = 1 : 14.5**** Approx. Flow at an air drive of 6 bar and an outlet of 0 bar

MAXIMATOR ® - Complete Solutions in the High-Pressure Technique5

Power Packs for Oil Service

Type S 60

Hydraulic Unit
Configuration
The power pack contains thefollowing components:• MAXIMATOR pump S60• Aluminium tank of 6.5 liter• Manifold block with pressure outlet• Pressure gauge 0 – 600 bar,Ø 63 mm• Air control unit
• Pneumatically operated relief valve

Advantages• Small dimensions

Application• Low weightThis power pack will be used wherever is to be built• Easy to handle• No energy consumption after
having reached the set final
pressure• Compressed air drive, no explosion
hazardup a hydraulic pressure locally. It is provided for all
functions within the tool and clamping hydraulic, e.g.
for• pressure tests• pulling-off devices• shop presses• and many more

Technical features
Pump model:

S 60

Pressure ratio:

1 : 61

Maximum outlet pressure:

610 barMaximum air drive pressure: 10 bar
Maximum flow capacity:

approx. 2.7 l/min

Approx. dimensions of

260 x 220

the power pack (LxWxH):

x 350 mmApprox. weight of the power pack: 11 kg

6

MAXIMATOR ® - Complete Solutions in the High-Pressure TechniquePower Packs for Oil Service

Type MO 72 D

Hydraulic Unit
Configuration
The power pack contains thefollowing components:• MAXIMATOR pump MO72D• Aluminium tank of 6.5 liter• Manifold block with pressure outlet• Pressure gauge 0-600 bar,Ø 63 mm• Air control unit
• Safety valve in the air line
• Pneumatically operated relief valve

Advantages• No damage of the sheet surface• Optimized feed - high cycle time
• No energy consumption after
having reached the set final
pressure• No heating of the pressure medium

Application
The power pack presented here will be used in thefeed units at eccentric presses. It keeps the hydraulicpressure in the cylinders for the pressure drum
constant. So will be reached a continuous contactpressure which permits an optimized feed of the sheet
to be stamped.

Technical features
Pump model:

MO 72 D

Pressure ratio:

1 : 86

Maximum outlet pressure:860 barMaximum air drive pressure: 7 bar
Maximum flow capacity:

approx. 1.2 l/min

Approx. dimensions of

260 x 240

the power pack (LxWxH):

x 250 mmApprox. weight of the power pack: 9.5 kg

MAXIMATOR ® - Complete Solutions in the High-Pressure Technique7

Power Packs for Oil Service

Type MO 72

Hydraulic Unit
Configuration
The power pack contains thefollowing components:• MAXIMATOR pump MO72
• Aluminium tank of 6.5 liter• Valve block• 5 pces. electrically operated
directional valves• Pressure release valve• High pressure filter

Advantages• Constant pressing of the feed rolls• Exact dosage of the sealingmaterial

Application
This MAXIMATOR hydraulic unit will be used in a line

• No energy consumption after
having reached the set final
pressure

for manufacturing insulating glass. The mounted• No heating of the pressure medium

insulating glass pane by means of a feed roll.

directional valves are actuating hydraulic cylinders
which will be pressed on every side against the
Furthermore, the power pack actuates a hydrauliccylinder applying the sealing material in exact
dosages to the glass panes.

Technical features
Pump model:

MO 72

Pressure ratio:

1 : 86

Maximum outlet pressure:860 barMaximum air drive pressure: 10 bar
Maximum flow capacity:

approx. 0.7 l/min

Approx. dimensions of

315 x 220

the power pack (LxWxH):

x 270 mmApprox. weight of the power pack: 12 kg

8

MAXIMATOR ® - Complete Solutions in the High-Pressure TechniquePower Packs for Oil Service

Type MO 22 D

Hydraulic Unit
Configuration
The power pack contains thefollowing components:• MAXIMATOR pump MO22D• Aluminium tank of 6.5 liter• Pressure gauge 0-250 bar,Ø 63 mm• Accumulator, volume 0.7 literwith safety devices• Flange block with valves,nominal size 6• Oil collecting recipient

Advantages• Almost pulsation-free pressurebuild-up

Application• Continuous movement of the lid

This power pack will be used for moving and locking,• Compact design, minimum spacerequirement

by means of a hydraulic cylinder, cover lids of• No energy consumption after
having reached the set final
pressurecontinuously with constant speed.

• No heating of the pressure medium

centrifuges. The lid moving has to be realized

The power pack is designed for being fixed to walls.
In case of damage, an air collecting trough receives
the oil quantity of the tank.

Technical features
Pump model:

MO 22 D

Pressure ratio:

1 : 28Maximum outlet pressure:

280 barMaximum air drive pressure: 9 bar
Maximum flow capacity:

approx. 3.9 l/min

Approx. dimensions of

400 x 250

the power pack (LxWxH):

x 650 mmApprox. weight of the power pack: 25 kg

MAXIMATOR ® - Complete Solutions in the High-Pressure Technique

9Power Packs for Hydraulic Clamping Applications

Type S 25 D

Clamping Unit
Configuration
The power pack contains thefollowing components:• MAXIMATOR pump S 25 D
• Aluminium tank of 6.5 liter withaccessories• Protection hood with integrated
operating instruments• Air control unit
• Pressure gauge 0-250 bar,Ø 63 mm• Air operated directional valves• Pressure relief valves• Quick couplings

Advantages• Almost pulsation-free pressurebuild-up• Compact design, minimum spacerequirement• No energy consumption after
having reached the set final
pressure• No heating of the pressure medium

Application
This MAXIMATOR clamping unit as portable andcompact hood version will be used in all ranges of thehydraulic clamping and tool system.
In dependence on the required pressure and delivery
rate there are available pumps with different pressure
ratios and flow rates.
Ranges of application are for example• hydraulic clamping tools• actuating of cylinders• application in riveting tools

Technical features• hydraulic presses

Pump model:

S 25 D• lifting tables, elevating platforms

Pressure ratio:

1 : 25

Maximum outlet pressure:

250 barMaximum air drive pressure: 10 bar
Maximum flow capacity:

approx. 12 l/min

Approx. dimensions of

310 x 260

the power pack (LxWxH):

x 500 mmApprox. weight of the power pack: 33 kg

10

MAXIMATOR ® - Complete Solutions in the High-Pressure TechniquePower Packs for Hydraulic Clamping Applications

Clamping Units

Pneumatic standard design

1 Clamping circuit – single acting

1 Clamping circuit – double acting

1* EZ (P)

1* DZ (P)Model key

Order code

S 25 D/FR/13/T/H/0- 250 (63)/1*EZ ((P) /SV
S 60 D/FR/13/T/H/0- 600 (63)/1*EZ ((P) /SV
S 100 D/FR/13/T/H/0-1000 (63)/1*EZ ((P) /SV

VP 54.00.34.05
VP 54.00.34.07
VP 54.00.34.08

Model key

Order code

S 25 D/FR/13/T/H/0- 250 (63) /1*DZ ((P) /SV VP 54.00.34.01
S 60 D/FR/13/T/H/0- 600 (63) /1*DZ ((P) /SV VP 54.00.34.03
S 100 D/FR/13/T/H/0-1000 (63) /1*DZ ((P) /SV VP 54.00.34.04

2 Clamping circuits – single acting

2 Clamping ciruits – double acting

2* EZ (P)2* DZ (P)Model key

Order code

25 D/FR/13/T/H/0- 250 (63) /2*EZ ((P) /SV
60 D/FR/13/T/H/0- 600 (63) /2*EZ ((P) /SV
100 D/FR/13/T/H/0-1000 (63) /2*EZ ((P) /SV

VP 54.00.34.13
VP 54.00.34.15
VP 54.00.34.16

Model key

Order code

S 25 D/FR/13/T/H/0- 250 (63) /2*DZ ((P) /SV VP 54.00.34.09
S 60 D/FR/13/T/H/0- 600 (63) /2*DZ ((P) /SV VP 54.00.34.11
S 100 D/FR/13/T/H/0-1000 (63) /2*DZ ((P) /SV VP 54.00.34.12

For ordering an electric drive, please specify voltage, e. g.: VP 54.00.34.01-24 V ; VP 54.00.34.01-220 V

PZ 3-1 (R)P 3-1
Pilot airMarked with A; A1; A2 ...
Marked with B; B1; B2 ...
Marked with Y; Y1; Y2 ...

Width:
Depth:Height:Weight:

310 mm
260 mm
500 mmapprox. 33 kg

MAXIMATOR ® - Complete Solutions in the High-Pressure Technique

11

Power Packs for Hydraulic Clamping Applications

Type S 35

Clamping Unit
Configuration
The power pack contains thefollowing components:• MAXIMATOR pump S35• Aluminium tank of 6.5 liter withaccessories• Protection hood
• Air control unit
• Pressure gauge 0-400 bar,Ø 63 mm• Air operated directional valves

Advantages• High pressure, high flow capacity• Compressed-air drive, easy tomaintain• No energy consumption after
having reached the set final
pressure• No heating of the pressure medium

Technical features
Pump model:

S 35

Pressure ratio:

1 : 39Maximum outlet pressure:390 barApplication
The clamping unit presented here will be used for
driving very different tools. Its universal applicability
is due to its robust and simple constructional design.
In the above example, the mobile pressure generating
unit is provided for operating a hydraulically actuatedchain cutter for being used in the underground mining.
Further applications:• hydraulic punch tools• hydraulic clamping and cutting tools• actuating of cylinders• hydraulic presses

Maximum air drive pressure: 10 bar
Maximum flow capacity:

approx. 4.3 l/min

Approx. dimensions of

310 x 240

the power pack (LxWxH):

x 420 mmApprox. weight of the power pack: 18 kg

12

MAXIMATOR ® - Complete Solutions in the High-Pressure TechniquePower Packs for Hydraulic Clamping Applications

Type MO 22 SN

Clamping Unit
Configuration
The power pack contains thefollowing components:• MAXIMATOR pump MO22SN• Valve block with integrated oil tank• 3/2 directional valve, nominal size 6• 1 pce. air pilot switch each to startand stop the unit at a pre-definedpressure• Pressure gauge 0-250 bar, Ø 63 mm• Oil sight glass• Pressure relief valves• Filling socket and ventilation

Advantages• No energy consumption after
having reached the set final
pressure because the pump stops
automatically• Long pressure holding times
without energy consumption

Application
This hydropneumatic clamping unit has been
designed in particular for being used at NC circularindexing tables.

• Pump substitutes leakage losses
through automatic re-delivery

In addition to that, this handy and compact hydraulic• Simple mounting, handy
construction

pressures and low flow rates will be used withunit is of universal applicability wherever hydraulicminimum space requirement.
The mounting position of the power pack is just as
you like, the filler and ventilator can be mounted on
three sides.

Technical features
Pump model:

MO 22 SN

Pressure ratio:

1 : 28Maximum outlet pressure:

280 barMaximum air drive pressure: 10 bar
Maximum flow capacity:

approx. 2.2 l/min

Approx. dimensions of

180 x 320

the power pack (LxWxH):

x 80 mmApprox. weight of the power pack: 6 kg

MAXIMATOR ® - Complete Solutions in the High-Pressure Technique

13

Power Packs for Water Service

Type M 72-01

Hydraulic Power Pack
Configuration
The power pack contains thefollowing components:• MAXIMATOR pump M 72-01• Hand lever• Air control unit, type "C1"
• Air safety valve• Tank of stainless steel, volume 13 liter• Pressure gauge 0-400 bar ø 100• Relief valve, type EV• Pressure outlet with shut-off valve,type AV• Protective frame• Adapter for connecting hoses

Advantages• Power pack in rough and damage
protected design• Compact system• Corrosion resistant due to stainlesssteel design• No energy consumption when the set
operating pressure is reached once
• Pressure can be built up, even there
is no shop air available• Easy to operate

Application
This compact power pack in portable stainless steel
frame design is suitable for mobile applications.
The pressure can be built up in short term by using
the hand lever even there is no shop air available.
Examples:• Burst pressure tests• Internal high pressure forming• Leakage tests• Etc.

Technical features
Pump model:

M 72-01

Pressure ratio:

1 : 86

Maximum outlet pressure:

400 barMaximum air drive pressure: 4.5 bar
Maximum flow capacity:

approx. 0.7 l/min

Approx. dimensions of

420 x 350

the power pack (LxWxH):

x 450 mmApprox. weight of the power pack: 22 kg

14

MAXIMATOR ® - Complete Solutions in the High-Pressure TechniquePower Packs for Water Service

Type G 25-2 LVE

Hydraulic Power Pack
Configuration
The power pack contains thefollowing components:• MAXIMATOR pump G 25-2 LVE• Air control unit, type "C2"
• Stainless steel tank, volume 30 liter• Carrying handles• Manifold block of stainless steel• Pressure gauge 0-600 bar ø 100• Relief valve, type EV• Pressure outlet with shut-off valve• Adapters in common sizes

Advantages• Ready made and complete solution• Corrosion resistant stainless steel design

Application• Suitable for series tests

This portable hydraulic power pack can be used in all• Can be connected i. e. to the watersupply• Filling and pressure build-up in
short time through pump withdouble air drive headapplications where pressure test shall be realized, i. efor TÜV approvals.
Examples:• Receivers for fire extinguishers• Breathing air cylinder• Compressed gas accumulators• Gas cylinders• Etc.

Technical features
Pump model:

G 25-2 LVE

Pressure ratio:

1 : 56

Maximum outlet pressure:560 barMaximum air drive pressure: 10 bar
Maximum flow capacity:

approx. 6.19 l/min

Approx. dimensions of

490 x 340

the power pack (LxWxH):

x 700 mmApprox. weight of the power pack: 34 kg

MAXIMATOR ® - Complete Solutions in the High-Pressure Technique

15

Power Packs for Water Service

Type G 500-2 L

Hydraulic Power Pack
Configuration
The power pack contains thefollowing components:• MAXIMATOR pump G 500-2 L• Air control unit, type "C2"
• Air safety valve• Stainless steel tank, volume 70 liter• Mobile design• Pressure gauge 0-7,000 bar Ø 160• Relief valve, type EV• Pressure outlet with shut-off valve• All wetter materials of stainlesssteel

Advantages• Very high test pressures can beachieved• Wide adjustable pressure range• Mobile pack
• Safe design

Application
This mobile MAXIMATOR system can be used in all
applications where high pressure and low flow rates
are required.
Examples:• Pressure and leak tests on receivers• Burst pressure tests on hp hoses and systems• etc.

Technical features
Pump model:

G 500-2 L

Pressure ratio:

1 : 1,038

Maximum outlet pressure:

5,500 bar

Maximum air drive pressure: 6.5 bar
Maximum flow capacity:

0.3 l/minApprox. dimensions of

620 x 480

the power pack (LxWxH):

x 820 mmApprox. weight of the power pack: 48 kg

16

MAXIMATOR ® - Complete Solutions in the High-Pressure TechniquePower Packs for Water Service

Type DPD200 / G400L

Test Station
Configuration
The power pack contains thefollowing components:• MAXIMATOR pump DPD200• MAXIMATOR pump G 400 L• Electric pump 5.5 KW• Air control units, type "C2"
• Shut-off valves and line filters• Stainless steel frame on wheels• Pressure transducer with digital
display• Pressure gauge 0-250 bar Ø 100• Electric directional valves• Pressure relief valves• All wetted materials of stainlesssteel

Advantages• High flow capacity

Application• High outlet pressures• Rough stainless steel design• Directly connected to the watersupply• Suitable for special liquids

Technical features
Pump models:

as above

Pressure ratio:

1 : 286 / 1:398

Maximum outlet pressure:

2,200 bar

This mobile power pack can be used on construction
sites for pressure and leak tests on pipelines.
Three pumps with different pressure ratios andpressure ranges are pneumatically or electricallydriven.
It is built in user friendly design with control cabinet
for pressure observation and regulation.
Example:• Power pack for injecting corrosion inhibitors into
pipelines and systems• For pressure and leak tests• Etc.

Maximum air drive pressure: 5.5 bar
Maximum flow capacity:

approx. 20 l/min

Approx. dimensions of

950 x 1250

the power pack (LxWxH):

x 880 mmApprox. weight of the power pack: 180 kg

MAXIMATOR ® - Complete Solutions in the High-Pressure Technique

17

Power Packs for Water Service

Type G 25 DVE

Hydraulic Power Pack
Configuration
The power pack contains thefollowing components:• MAXIMATOR pump G 25 DVE• Air control unit, type "C2"
• Stainless steel tank, volume 70 liter,with accessories• Workshop chart design• Pressure gauge 0-250 ø 160• Accumulator 2.5 Liter / 330 bar• Pressure relief valve• Proportional valve• Digital pressure transducer anddisplay• Electric box with power supply• Complete drive hydraulics

Application
This complete solution for applications in water
hydraulics permits pulsation-free pressure tests on test

Advantages• Pulsation-free pressure tests• Continuous control• Reproducibility: ± 1 bar• Modulair design with electronic
measuring and regulating
techniquespecimen with an excellent electronic pressure
regulation.
Examples:• Burst pressure tests• Leak tests• Internal high pressure forming• Long term tests• Etc.

Technical features
Pump model:

G 25 DVE

Pressure ratio:

1 : 27

Maximum outlet pressure:

250 barMaximum air drive pressure: 9 bar
Maximum flow capacity:

11 l/minApprox. dimensions of1000 x 700

the power pack (LxWxH):

x 550 mmApprox. weight of the power pack: 65 kg

18

MAXIMATOR ® - Complete Solutions in the High-Pressure TechniquePower Packs for Water Service

Type M 37 LVE

Hydraulic Power Pack
Configuration
The power pack contains thefollowing components:• MAXIMATOR pump M 37 LVE• Air control unit, type "C1"
• Stainless steel tank, volume 13 liter,with accessories• On wheels• Pressure gauge 0-400 Ø 100 for
accumulator• Accumulator 2.5 Liter / 330 bar• Pressure relief valve• Pressure release valve• Pressure regulator at the outlet• Outlet pressure gauge 0-40 barØ 63Application
Advantages• Accurate regulation of the outletpressure• Easy to operate• All wetted parts of corrosion
resistant materials• Energy saving• No cooling required

Technical features
Pump model:

M 37 LVE

Pressure ratio:

1 : 46

Maximum outlet pressure:

400 barThis system can be used in all applications where
small pressure tests have to be made.
By combining pressure generation, pressure storage
and pressure regulation, it is possible to get stored
energy, in this case a water pressure of 40 bar.
Examples:• Burst pressure tests• Control of pipelines• Leak tests• Internal high pressure forming• Compression of materials•Etc.

Maximum air drive pressure: 8.5 bar
Maximum flow capacity:

1.3 l/minApprox. dimensions of

420 x 350

the power pack (LxWxH):

x 550 mmApprox. weight of the power pack: 23 kg

MAXIMATOR ® - Complete Solutions in the High-Pressure Technique

19

Power Packs for Water Service

Type M 189 L / M 189-2 L

Hydraulic Power Pack
Configuration
The power pack contains thefollowing components:• MAXIMATOR pumps,
M189L and M189-2L• Air control units, type "C1"
• Air safety valves• Aluminium tank, volume 13 liter,with accessories• On wheels• Pressure gauges 0-1,600 Ø 100,
0-2,500 Ø 160• Pressure relief valves, type EV• Shut-off valves, type AV1• High pressure hoses, type SK 6005
• Quick couplings

Application

Advantages• Pressure build-up in two different
ranges at the same time
• Automatic pumping in case ofleakages• Easy to operate• High mobility through compact
design• Suitable for various liquids

Technical features
Pump models:

M189L /
M189-2L

Pressure ratio:

1:220 / 1:450

Maximum outlet pressure:

2,500 bar

Two MAXIMATOR pumps with different pressure
ratios are used for generating the pressure forhydraulic interference fits. So cams and gear parts
can be expanded and displaced at the same time.
These power packs are especially designed on
customers request depending on the application andtheir specific requirements.
Examples• Hydraulic interference fits
• Expansion and displacement of hubs
• Actuation of hydraulic stamps• Lifting equipment• Torque tensioning of screws• Etc.

Maximum air drive pressure: 5.5 bar
Maximum flow capacity:

0.48 l/min

Approx. dimensions of

310 x 240

the power pack (LxWxH):

x 450 mmApprox. weight of the power pack: 17.5 kg

20

MAXIMATOR ® - Complete Solutions in the High-Pressure TechniquePower Packs for Water Service

Type G 300 L

Hydraulic Power Pack
Configuration
The power pack contains thefollowing components:• MAXIMATOR pump G 300 L• Air control unit, type "C2"
• Air safety valve• Aluminium tank, volume 13 liter,with accessories• On wheels• Outlet pressure gauge 0-4,000Ø 160• Pressure relief valve, type EV• 2 Pressure outlets with shut-off
valve each, type AV2• 2 High pressure hoses,
type SK 6005
• Protective frame in special design

Application

Advantages• Easy to operate• Rough design for difficult ambientconditions• No cooling required• System-integrated safety devices• Suitable for different hydraulicliquids as well as for water• All wetted parts of corrosion
resistant materials

Technical features
Pump model:

G 300 L

Pressure ratio:

1 : 314

Maximum outlet pressure:

3,140 bar

This mobile power pack offers a wide range ofapplications. It can be used to loose and tighten
interference fits as well as to generate the pressure forscrew clamping devices.
Examples• Density tests• Burst pressure tests• Leak tests• Autofrettage• Long term tests• Etc.

Maximum air drive pressure: 10 bar
Maximum flow capacity:

0.7 l/minApprox. dimensions of

340 x 290

the power pack (LxWxH):

x 790 mmApprox. weight of the power pack: 29 kg

MAXIMATOR ® - Complete Solutions in the High-Pressure Technique21

Test Benches
MAXIMATOR has a vast know-how

Our test bench line comprises:with regard to concept, development,• pressure test benches

construction and manufacturing of• bursting pressure test benches

test benches, pressure generating• pulse and durability test benches

systems and autofrettage systems.

• leak test benches

Hoses, pipes, tanks, accumulators, valves, fittings, plastic• functional test benches

and ceramic components as well as in particular• high-pressure generating systems

components of the diesel inyection technique (rails,• autofrettage systems• mandrel extraction machines for

nozzles, nozzle holders, inyectors)

hoses

and other vehicle components (e.g.

• air bag filling and controlling

air bag cartridges, camshafts andsystems

intermediate shafts, gears) will betested and manufactured successfully
by means of MAXIMATOR systems.

Furthermore we offer you worldwide an extensive service

As complete supplier having many years of experiencesfrom the assembly and commissioning over co-worker

with regard to components, power packs and systems, wetraining up to rotational maintenance of your machine.

offer our customers individual solutions being tailored toyour special requirements. From the preparation of the

As development co-partner of the automobile andperformance specification up to thecomponents supplying industry we arecommissioning and training of theextremely familiar with the demands on

personnel you will be accompanied by

testing, taking down and documenting

our experienced engineers andof the test results and test datatechnicians so that your test task will beadministration. On your request, we

solved optimally.

also take on and document the

A program of benchard systems, ameasuring equipment check test anddesigned modular system of

the calibration of the installed

standardized components as well as

measuring instruments.

customized special solutions are available for you andIn our service center we can realize for you pressure,cover the complete range of pressure generation andbursting pressure and pulse pressure tests as well as aut-pressure test.

ofrettage services. Feasability studies, structural tests, test

MAXIMATOR test benches, pressure

and autofrettage of pilot productions

generating and autofrettage systems

or small batches are possible without

reach pressures up to max. 15,000

any problem. This scope of offers will

bar and can be operated with abe extended continuously.

number of liquids, such as oil, water,
HFA, HFC, pentosin, brake fluid or

Please consult us.

gases (e.g. nitrogen, oxygen, helium).

22

MAXIMATOR ® - Complete Solutions in the High-Pressure TechniqueAccessories
MAXIMATOR offers a complete line of high pressure equip-

Piston shut-off valves for liquids and non-ment and supplies various accessories for all pneumatic

combustible gases from 150 toand hydraulic applications. Most items can be shipped ex

1,000 bar
Air control units for pumps and boosters,

stock or in short term.
Adapter

Adapter

Adapterfor pumps and boosters resp. manifold blocks toavailable in 1/4" BSP to 1/2"

1,000 bar with female BSP thread for highBSP

pressure hoses with 60° sealing cone and swivel

Pressure gauges, Ø 63 mm

nut

Pressure gauges, Ø 100 mm

for pumps and boosters resp. manifold blocks to

Pressure gauges, Ø 160 mm

1,000 bar with female BSP thread for highGauge connections for HP fittings andpressure tubing

valves with SF...CX to 1,400

for high pressure valves and fittings with coned-bar and F...C to 4,200 bar

and-threaded-connectors with female BSP

SF...CX to 1,400 bar and F...C

thread up to 4,200 bar
Adapterfor high pressure valves and fittings for highpressure hoses with 60° sealing cone and swivel
nut up to 4,200 bar

to 4,200 bar
Gauge connections for high pressure
fittings and valves with BSP
thread to 1,000 bar for higher

Manually or air operated shut-off valves
Manifold blocks for hydraulic units with relief valve
Manifold blocks for pumps and boosters from 400 bar to2,500 bar
Manifold blocks for pumps and boosters from 250 bar to2,500 bar
Manifold blocks with directional valve and pressure relief
valve for hydraulic units to 700 bar
Manifold blocks for oil pumps to 700 bar
Fittings

Gauge connections for HP tubing with(elbows, tees, crosses, couplings, bulkhead
couplings

pressures to 1,400 bar and to
4,200 bar
Pneumatic valves (electrically operated)for pumps, boosters andhydraulic units
Safety valves for compressed air andnon-toxic, non-combustible
gases from 0.5 to 42 bar,nominal width (DN) 10
Safety valves for vapors, gases andliquids from 0.5 to 250 bar,Gas receivers

nominal width (DN) 15

Accumulators

Safety valves for liquids and gases (non-Pressure transducers for gas and liquid service from 10 bar
to 4,000 bar

combustible/combustible) from
3.4 to 414 bar

Air receiver tanks from 0.75 liter to 350 liter
Pressure regulators for hydraulic units and booster stations
for gases

Safety valves for liquids and noncombustible gases from 120 to
1,000 bar

High pressure hoses, nominal size (DN) 5

Safety valves for liquids and non-High pressure hoses, nominal size (DN) 8

combustible gases from 1,000

Hydraulic tanks, aluminium nominal size 6.5 to 70 literto 4,400 bar

Hydraulic tanks, stainless steel, nominal size from 6.5 to
70 literDirectional seat valves for hydraulic units
to 500 bar

MAXIMATOR ® - Complete Solutions in the High-Pressure Technique23

High-pressure pumps
for different liquids(oil, water, emulsion etc.)
1 easy to maintain, ex-proof
1 low energy consumption
1 operating pressures up to max. 5,500 bar

Compressed Air Amplifiers
1 For increasing air pressure
1 Specific air pressure amplification
to suit your requirements
1 Connection to electrical supply not necessary
1 Operating pressure max. 40 bar

High Pressure Compressors
1 For pressurizing gases (nitrogen, oxygen, inert gases)
1 Simple handling
1 Intrinsically safe and explosion proof i. e. notelectromotive, but pneumatically powered
1 Operating pressure max. 1,000 bar

Gas Assist Injection Systems
1 Compressor stations with pneumatic, electric or hydraulic drive
1 Control modules with 2, 4 or 8 valves
1 Control modules with integrated booster station
1 External core pull control systems

High Pressure Valves, Fittings, Tubing
1 Stainless steel design
1 Temperatures from -250° C to +650° C
for liquids and gases
1 Maximum outlet pressures up to 10,500 bar

Your Representative:

3999.0867 | 1000 DSB 12/2007

Factory

Internet

MAXIMATOR GmbHWalkenrieder Str. 15
D-37449 Zorge / Germany
www.maximator.de

Telephon: ++49 5586 / 80 30
Facsimile: ++49 5586 / 8 03 30 40
eMail: info @ maximator.de

All technical and dimensional information subject to change. All general Terms and Conditionsof sale, including limitations of our liability, apply to all products and services sold.

MAXIMATOR GmbH