Titan PoPT8900, PoPT4900, PoPT6900, PoPT12000 User Manual

Operating manual

Betriebsanleitung ............p. 28

Mode d’emploi ................. p. 56

Airless high-pressure spraying unit Airless Hochdruck-Spritzgerät Groupe de projection à haute pression

D F

PowrTwin Plus

Model 0290012 (PT4900)

0290013 (PT6900) 0290018 (PT8900)

Model 0290032 (PT4900)

Edition 9 / 2016 0290 935L Ausgabe

0290016 (PT12000)

Original Operating Manual

Airless units develop extremely high spraying pressures.

Never put your ngers, hands or any other parts of the body into the spray jet!

Never point the spray gun at yourself, other persons or animals. Never use the spray gun without safety guard.

Warning!

Attention: Danger of injury by injection!

Do not treat a spraying injury as a harmless cut. In case of injury to the skin through coating materials or solvents, consult a doctor immediately for quick and expert treatment. Inform the doctor about the coating material or solvent used.

The operating instructions state that the following points must always be observed before starting up:

1. Faulty units must not be used.

2. Secure Titan spray gun using the safety catch on the trigger.

3. Ensure that the unit is properly earthed.

4. Check allowable operating pressure of high-pressure hose and spray gun.

5. Check all connections for leaks.

The instructions regarding regular cleaning and maintenance of the unit must be strictly observed.

Before any work is done on the unit or for every break in work the following rules must be observed:

1. Release the pressure from spray gun and hose.

2. Secure the Titan spray gun using the safety catch on the trigger.

3. Switch o unit.

Be safety conscious!

2 PowrTwin Plus

Contents

Page

1. Safety regulations for Airless spraying ...................................... 2

1.1 Explanation of symbols used .............................................................. 2

1.2 Electrical safety ......................................................................................... 3

1.3 Gasoline engine safety .......................................................................... 4

1.4 Fueling (gas engine) ............................................................................... 4

2. General view of application ............................................................. 5

2.1 Application ................................................................................................ 5

2.2 Coating materials .................................................................................... 5

3. Description of unit................................................................................ 5

3.1 Airless process .......................................................................................... 5

3.2 Functioning of the unit ......................................................................... 5

3.3 System diagram - gasoline PT units .................................................. 6

3.4 System diagram - electric PT units .................................................... 7

3.5 Technical data for PT units ................................................................... 8

3.6 Airless Spray Tip Recommendation Chart ...................................... 9

4. Operation ................................................................................................10

4.1 Setup .......................................................................................................... 10

4.2 Preparing a new sprayer ..................................................................... 11

4.3 Preparing to paint ................................................................................. 12

4.4 Painting ..................................................................................................... 13

4.5 Pressure relief procedure ...................................................................13

5. Cleanup .................................................................................................... 14

5.1 Special cleanup instructions for use with

ammable solvents ..............................................................................14

5.2 Cleaning the sprayer ............................................................................ 14

5.3 Cleaning a clogged tip ........................................................................ 14

Page

7. Troubleshooting .................................................................................25

7.1 Airless gun ...............................................................................................25

7.2 Fluid section ............................................................................................ 25

7.3 Hydraulic motors ................................................................................... 26

7.4 Spray patterns ........................................................................................27

Accessories and spare parts ........................................................................84

Spare parts list for the main assembly .................................................. 84/85

Spare parts list for the cart assembly .................................................... 86/87

Spare parts list for the hydraulic system .............................................. 88/89

Spare parts list for the hydraulic motor ............................................... 90/91

Spare parts list for the uid section • PT4900 ..................................... 92/93

Spare parts list for the uid section •

PT6900 / PT8900 / PT12000 ...................................................................... 94/95

Spare parts list for gas convertokit ........................................................ 96/97

Spare parts list for electric convertokit (230V) ................................... 98/99

Spare parts list for the high-pressure lter ..............................................100

Spare parts list for belt guard assembly ....................................................101

Spare parts list for bleed hose assembly with valve .............................102

Spare parts list for bleed valve .....................................................................103

Spare parts list fo siphon hose assembly ..................................................104

Connection diagram (230V) .......................................................................105

Accessories for PT units ...............................................................................106

Gun manifold assemblies (optional) ..........................................................108

Warranty .............................................................................................................109

6. Maintenance..........................................................................................15

6.1 Daily maintenance ................................................................................ 15

6.2 Maintaining the lter assembly........................................................15

6.3 Maintaining the hydraulic system ................................................... 17

6.4 Maintaining the uid section ............................................................ 17

6.5 Basic engine maintenance ................................................................. 17

6.6 Replacing the motor brushes (120V electric convertokit) ...... 18

6.7 Replacing the belt ................................................................................. 19

6.8 Servicing the hydraulic motor .......................................................... 20

6.9 Servicing the uid section .................................................................. 22

6.10 SAE O-ring tting installation ...........................................................24

PowrTwin Plus 1

Safety precautions

1. Safety regulations for Airless spraying

1.1 Explanation of symbols used

This manual contains information that must be read and understood before using the equipment. When you come to an area that has one of the following symbols, pay particular attention and make certain to heed the safeguard.

This symbol indicates a potential hazard that may cause serious injury or loss of life. Important safety information will follow.

This symbol indicates a potential hazard to you or to the equipment. Important information that

tention

tells how to prevent damage to the equipment or how to avoid causes of minor injuries will follow.

Danger of skin injection

Danger of fire from solvent and paint fumes

Danger of explosion from solvent, paint fumes and incompatible materials

Danger of injury from inhalation of harmful vapors

• All accessories must be rated at or above the maximum

operating pressure range of the sprayer. This includes spray tips, guns, extensions, and hose.

HAZARD

The paint hose can develop leaks from wear, kinking and abuse. A leak can inject material into the skin. Inspect the hose before each use.

PREVENTION:

• Avoid sharp bending or kinking of the high-pressure hose. The

smallest bending radius amounts to about 20 cm.

• Do not drive over the high-pressure hose. Protect against

sharp objects and edges.

• Replace any damaged high-pressure hose immediately.

• Never repair defective high-pressure hoses yourself!

• Electrostatic charging of spray guns and the high-pressure

hose is discharged through the high-pressure hose. For this reason the electric resistance between the connections of the high-pressure hose must be equal to or lower than 1M.

• For reasons of function, safety and durability use only original

Titan high-pressure hoses.

• Before each use, check all hoses for cuts, leaks, abrasion

or bulging of cover. Check for damage or movement of couplings. Immediately replace the hose if any of these

conditions exist. Never repair a paint hose. Replace it with

another earthed high-pressure hose.

• Make sure power cord, air hose and spray hoses are routed in

such a manner to minimize slip, trip and fall hazard.

: HIGH PRESSURE HOSE

Notes give important information which should be given special attention.

HAZARD: INJECTION INJURY

A high pressure stream produced by this equipment can pierce the skin and underlying tissues, leading to serious injury and possible amputation.

PREVENTION:

• NEVER aim the gun at any part of the body.

• NEVER allow any part of the body to touch the uid stream. DO NOT allow body to touch a leak in the uid hose.

• NEVER put your hand in front of the gun. Gloves will not

provide protection against an injection injury.

• ALWAYS lock the gun trigger, shut the uid pump o and

release all pressure before servicing, cleaning the tip guard, changing tips, or leaving unattended. Pressure will not be

released by turning o the engine. The PRIME/SPRAY valve

or pressure bleed valve must be turned to their appropriate positions to relieve system pressure.

• ALWAYS keep tip guard in place while spraying. The tip guard

provides some protection but is mainly a warning device.

• ALWAYS remove the spray tip before ushing or cleaning the

system.

• NEVER use a spray gun without a working trigger lock and

trigger guard in place.

HAZARD: EXPLOSION OR FIRE

Flammable vapors, such as solvent and paint vapors, in work area can ignite or explode.

PREVENTION:

• Use equipment only in well ventilated area. Keep a good

supply of fresh air moving through the area to keep the air within the spray area free from accumulation of ammable

vapors. Keep pump assembly in well ventilated area. Do not

spray pump assembly.

• Electric models only - Do not use materials with a ashpoint

below 38º C (100º F). Flashpoint is the temperature at which a uid can produce enough vapors to ignite.

• Gas models only - Do not ll fuel tank while engine is running

or hot; shut o engine and allow to cool. Fuel is ammable and can ignite or explode if spilled on a hot surface.

• Eliminate all ignition sources, such as pilot lights, cigarettes,

portable electric lamps and plastic drop cloths (potential static arc).

• Keep work area free of debris, including solvent, rags and

gasoline.

• Do not plug or unplug power cords, or turn power or light

switches on or o when ammable vapors are present.

• Ground equipment and conductive objects in work area.

Make sure the grounding cable (not equipped) is connected from the grounding lug to a true earth ground.

• Use only grounded hoses.

• Hold spray gun rmly to the side of a grounded pail when

triggering into pail.

• If there is static sparking or if you feel a shock, stop operation

immediately.

2 PowrTwin Plus

Safety precautions

• Know the contents of the paint and solvents being sprayed.

Read all Material Safety Data Sheets (MSDS) and container labels provided with the paints and solvents. Follow the paint and solvent manufacturer’s safety instructions.

• Do not use a paint or solvent containing halogenated

hydrocarbons. Such as chlorine, bleach, mildewcide, methylene chloride and trichloroethane. They are not compatible with aluminum. Contact the coating supplier about compatibility of material with aluminum.

• Keep a re extinguisher in work area.

HAZARD: HAZARDOUS VAPORS

Paints, solvents, and other materials can be harmful if inhaled or come in contact with body. Vapors can cause severe nausea, fainting, or poisoning.

1.2 Electric Safety

Electric models must be earthed. In the event of an electrical short circuit, earthing reduces the risk of electric shock by providing an escape wire for the electric current. This product is equipped with a cord having an earthing wire with an appropriate earthing plug. Connection to the mains only through a special feed point, e.g.

through an error protection insallation with INF < 30 mA.

DANGER — Work or repairs at the electrical equipment may only be carried out by a skilled electrician. No liability is assumed for incorrect installation. Switch the unit o. Before all repair work, unplug the power plug from the outlet.

Danger of short-circuits caused by water ingressing into the electrical

equipment. Never spray down the unit with high-pressure or high-

pressure steam cleaners.

PREVENTION:

• Wear respiratory protection when spraying. Read all

instructions supplied with the mask to be sure it will provide the necessary protection.

• All local regulations regarding protection against hazardous

vapors must be observed.

• Wear protective eyewear.

• Protective clothing, gloves and possibly skin protection cream

are necessary for the protection of the skin. Observe the regulations of the manufacturer concerning coating materials, solvents and cleaning agents in preparation, processing and cleaning units.

HAZARD: GENERAL

This product can cause severe injury or property damage.

PREVENTION:

• Follow all appropriate local, state, and national codes

governing ventilation, re prevention, and operation.

• Pulling the trigger causes a recoil force to the hand that is

holding the spray gun. The recoil force of the spray gun is particularly powerful when the tip has been removed and a high pressure has been set on the airless pump. When cleaning without a spray tip, set the pressure control knob to the lowest pressure.

• Use only manufacturer authorized parts. User assumes all

risks and liabilities when using parts that do not meet the minimum specications and safety devices of the pump manufacturer.

• ALWAYS follow the material manufacturer’s instructions for

safe handling of paint and solvents.

• Clean up all material and solvent spills immediately to prevent

slip hazard.

• Wear ear protection. This unit can produce noise levels above

85 dB(A).

• Never leave this equipment unattended. Keep away from

children or anyone not familiar with the operation of airless equipment.

• Do not spray on windy days.

• The device and all related liquids (i.e. hydraulic oil) must be

disposed of in an environmentally friendly way.

Work or repairs at the electrical equipment:

These may only be carried out by a skilled electrician. No liability is

assumed for incorrect installation.

Operating Temperature

This equipment will operate correctly in its intended ambient, at a minimum between +10°C and +40°C.

Relative Humidity

The equipment will operate correctly within an environment at 50% RH, +40°C. Higher RH may be allowed at lower temperatures.

Measures shall be taken by the Purchaser to avoid the harmful eects of occasional condensation.

Altitude

This equipment will operate correctly up to 2100 m above mean sea level.

Transportation and Storage

This equipment will withstand, or has been protected against, transportation and storage temperatures of -25°C to +55°C and for short periods up to +70°C.

It has been packaged to prevent damage from the eects of normal humidity, vibration and shock.

PowrTwin Plus 3

Safety precautions

Attention

1.3 Gasoline Engine Safety

1. Gas engines are designed to give safe and dependable service if operated according to instructions. Read and understand the engine manufacturer’s Owner’s Manual before operating the engine. Failure to do so could result in personal injury or equipment damage.

2. To prevent re hazards and to provide adequate ventilation, keep the engine at least 1 meter (3 feet) away from buildings and other equipment during operation. Do not place ammable objects close to the engine.

3. People who are not operating the device must stay away from the area of operation due to a possibility of burns from hot engine components or injury from any equipment the engine may be used to operate.

4. Know how to stop the engine quickly, and understand the operation of all controls. Never permit anyone to operate the

engine without proper instructions.

5. Gasoline is extremely ammable and is explosive under certain conditions.

6. Refuel in a well-ventilated area with the engine stopped. Do not smoke or allow ames or sparks in the refueling area or where gasoline is stored.

7. Do not overll the fuel tank. After refueling, make sure the tank cap is closed properly and securely.

8. Be careful not to spill fuel when refueling. Fuel vapor or spilled fuel may ignite. If any fuel is spilled, make sure the area is dry before starting the engine.

9. Never run the engine in an enclosed or conned area. Exhaust

contains poisonous carbon monoxide gas; exposure may cause loss of consciousness and may lead to death.

10. The muer becomes very hot during operation and remains hot for a while after stopping the engine. Be careful not to touch the muer while it is hot. To avoid severe burns or re hazards, let the engine cool before transporting it or storing it indoors.

11. Never ship/transport sprayer with gasoline in the tank.

1.4 Fueling (gas engine)

Gasoline is extremely flammable and is explosive under certain conditions.

Do not overll the gas tank. Overlling can cause the gas cap to become clogged with any particles in the gasoline which can cause a vaccum. Read

Attention

Fuel Specications

• Use automotive gasoline that has a pump octane number of

• Unleaded fuel produces fewer engine and spark plug deposits

• Never use stale or contaminated gasoline or an oil/gasoline

the gas engine’s instruction manual for fueling instructions.

86 or higher, or that has a research octane number of 91 or

higher. Use of a lower octane gasoline can cause persistent

“pinging” or heavy “spark knock” (a metallic rapping noise) which, if severe, can lead to engine damage.

If “spark knock” or “pinging” occurs at a steady engine speed under normal load, change brands of gasoline. If spark knock or pinging persists, consult an authorized dealer of the engine manufacturer. Failure to do so is considered misuse, and damage caused by misuse is not covered by the engine manufacturer’s limited warranty.

Occasionally you may experience light spark knock while operating under heavy loads. This is no cause for concern, it simply means your engine is operating eciently.

and extends the life of the exhaust system components.

mixture. Avoid getting dirt, dust, or water in the fuel tank.

DO NOT use this equipment to spray water or acid.

Do not lift by cart handle when loading or unloading. Device is very heavy. Three-person lift is required.

Gasolines Containing Alcohol

If you decide to use a gasoline containing alcohol (gasohol), be sure its octane rating is at least as high as that recommended by the engine manufacturer. There are two types of “gasohol”: one containing ethanol, and the other containing methanol. Do not use gasohol that contains more than 10% ethanol. Do not use gasoline containing methanol (methyl or wood alcohol) that does not also

contain co-solvents and corrosion inhibitors for methanol. Never

use gasoline containing more than 5% methanol, even if it has cosolvents and corrosion inhibitors.

Fuel system damage or engine performance

problems resulting from the use of fuels that contain alcohol is not covered under the warranty. The engine manufacturer cannot endorse the use of fuels containing methanol since evidence of their suitability is incomplete at this time.

Before buying gasoline from an unfamiliar station, try to nd out if the gasoline contains alcohol. If it does, conrm the type and percentage of alcohol used. If you notice any undesirable operating characteristics while using a gasoline that contains alcohol, or one that you think contains alcohol, switch to a gasoline that you know does not contain alcohol.

4 PowrTwin Plus

General view of application Description of unit

2. General view of application

2.1 Application

Priming and nal coating of large areas, sealing, impregnation, construction sanitation, façade protection and renovation, rust protection and building protection, roof coating, roof sealing, concrete sanitation, as well as heavy corrosion protection.

Examples of objects to be sprayed

Large-scale construction sites, underground construction, cooling towers, bridges, sewage treatment plants and terraces.

2.2 Coating materials

Processible coating materials

Pay attention to the Airless quality of the coating materials to be processed.

Latex paint, dispersion paints, re protection and thick lm materials, zinc dust and micaceous iron ore paints, Airless spray primer, sprayable glue, anti-corrosive agents, thick coating materials and bitumen-like coating materials.

No other materials should be used for spraying without Titan’s

approval.

Filtering

In spite of the high-pressure lter, ltering of the coating material is to be recommended in general (except when processing airless joint ller).

Stir coating material before commencement of work.

Make sure when stirring with motor-driven agitators

that no air bubbles are stirred in. Air bubbles disturb when spraying and can, in fact, lead to interruption of operation.

3. Description of unit

3.1 Airless process

The main area of application are thick layers of highly viscous coating material for large areas and a high consumption of material.

A piston pump takes in the coating material by suction and conveys it to the tip. Pressed through the tip at a pressure of up to a maximum of 3300-3600 PSI (228-248 bar, 24.4-24.8 MPa), the coating material is atomised. This high pressure has the eect of micro ne atomisation of the coating material.

As no air is used in this process, it is described as an AIRLESS process. This method of spraying has the advantages of nest atomisation,

cloudless operation and a smooth, bubble-free surface. As well as these, the advantages of the speed of work and convenience must be mentioned.

3.2 Functioning of the unit

The following section contains a brief description of the technical construction for better understanding of the function.

TITAN PowrTwin Plus (PT) are high-pressure spraying units driven by

either a gasoline engine or electric motor. The gasoline engine or electric motor (g. 1, item 1) drives the

hydraulic pump (3) by means of a V-belt which is under the belt cover (2). Hydraulic oil ows to the hydraulic motor (4) and then moves the piston up and down in the material feed pump (5).

The inlet valve is opened automatically by the upwards movement of the piston. The outlet valve is opened when the piston moves downward.

The coating material ows under high pressure through the highpressure hose to the spray gun. When the coating material exits from the tip it atomises.

The pressure control valve (6) controls the volume and the operating pressure of the coating material.

Viscosity

It is possible to work with high-viscosity coating materials with the devices.

If highly viscous coating materials cannot be sucked up, they must be diluted in accordance with the manufacturer’s instruction.

Two-component coating material

The appropriate processing time must be adhered to exactly. Within this time rinse through and clean the unit meticulously with the appropriate cleaning agents.

Coating materials with sharp-edged additional materials

These have a strong wear and tear eect on valves, high-pressure hose, spray gun and tip. The durability of these parts can be reduced appreciably through this.

4 5

PowrTwin Plus 5

Description of unit

3.3 System diagram - gasoline PT units

1 Extractable handle 2 Hydraulic motor 3 Oil cup for separating oil (separating oil prevents increased

wear and tear of the packings)

4 Pressure control knob 5 Relief valve handle: Turn left for circulation k Turn right for spray p 6 High-pressure lter

7 High-pressure hose outlet 8 V-belt under the belt cover 9 Bleed hose 10 Ball valve: horizontal position – hydraulic motor switched o vertical position – hydraulic motor switched on 11 Suction tube 12 Oil measuring stick 13 Gasoline engine

6 PowrTwin Plus

Description of unit

3.4 System diagram - electric PT units

1 Extractable handle 2 Hydraulic motor 3 Oil cup for separating oil (separating oil prevents increased

wear and tear of the packings)

4 Pressure control knob 5 Relief valve handle: Turn left for circulation k Turn right for spray p 6 High-pressure lter 7 High-pressure hose outlet 8 V-belt under the belt cover

9 Bleed hose 10 Ball valve: horizontal position – hydraulic motor switched o vertical position – hydraulic motor switched on 11 Suction tube 12 Oil measuring stick 13 Electric motor (230V)

14 ON/OFF switch

15 Control lamp that shows unit operational 16 Power Cord

PowrTwin Plus 7

Description of unit

3.5 Technical data for PT units

PT4900 Plus

(230V)

Gasoline engine, power

Subaru -------- 169cc, 5.7 Hp -------- -------- ------- Honda -------- -------- 163cc, 4.8 Hp 196cc, 5.5 Hp 270cc, 8.5 Hp

Fuel Capacity

-------- 0.95 US gal (3.6 l) 0.83 US gal (3.1 l) 0.83 US gal (3.1 l) 1.6 US gal (6.06 l)

Voltage

230 V~, 50 Hz -------- -------- -------- --------

Capacity

2.6 kW -------- -------- -------- --------

Power Cord

3 x 2.5 mm – 6 m -------- -------- -------- --------

Fuse Protection

16 A -------- -------- -------- --------

Max. operating pressure

Max. sound pressure level

80 dB (A)* 92 dB (A)* 98 dB (A)*

Max. size of tip with a spray gun

1-gun 0.031” – 0.79 mm 0.037” – 0.94 mm 0.050” – 1.27 mm 0.054” – 1.37 mm 0.059” – 1.50 mm 2-gun 0.028” – 0.71 mm 0.028” – 0.71 mm 0.033” – 0.84 mm 0.038” – 0.96 mm 0.040” – 1.01 mm 3-gun 0.022” – 0.56 mm 0.022” – 0.56 mm 0.023” – 0.58 mm 0.032” – 0.81 mm 0.034” – 0.86 mm 4-gun -------- -------- 0.019” – 0.48 mm 0.028” – 0.71 mm 0.030” – 0.76 mm 5-gun -------- -------- -------- 0.024” – 0.61 mm 0.026” – 0.66 mm 6-gun -------- -------- -------- -------- 0.024” – 0.61 mm

Max. volume ow

1.1 gal (4.2 l)/min 1.5 gal (5.7 l)/min 2.35 gal (8.9 l)/min 2.5 gal (9.5 l)/min 3.15 gal (11.9 l)/min

Weight

139 lbs. (63 kg) 132 lbs. (60 kg) 139 lbs. (63 kg) 154 lbs. (70 kg) 183 lbs. (83 kg)

Max. viscosity

Dimensions L x W x H

37.2” x 26.8” x 35” (946 x 680 x 890 mm)

Max. temperature of the coating material

Filter insert (standard equipment)

Hydraulic oil lling quantity

Max. tire pressure

Special high-pressure hose

PT4900 Plus

(gas)

22.8 MPa (228 bar, 3300 PSI) 24.8 MPa (248 bar, 3600 PSI)

50.000 mPa·s 65.000 mPa·s

DN 6 mm, 15 m (50’ x 1/4”), connection thread NPSM 1/4

PT6900 Plus PT8900 Plus PT12000 Plus

42.5” x 27” x 31” (1080

109ºF (43° C)

50 mesh, 18 in

5.9 l (1.56 gal) CoolFlo

0.2 MPa (2 bar, 30 PSI)

x 686 x 866 mm)

46” x 27” x 31” (1168 x 686 x

866 mm)

* Place of measurement: 1 m distance from unit and 1.60 m above reverberant oor, 120 bar (12 MPa) operating pressure.

8 PowrTwin Plus

Description of unit

3.6 Airless Spray Tip Recommendation Chart

Viscosity Filter Mesh Coating Orice Range Synergy™ (Fine Finish)

Light 100-150 Varnishes .009 - .011 .008 - .010

Lacquer Finishes (clear) .009 - .011 .008 - .010 Sanding Sealers .009 - .011 .008 - .010 Shellac (clear) .009 - .013 .008 - .012 Transparent Stain .011 - .013 .010 - .012 Water Sealers (clear) .011 - .013 .010 - .012

Medium 60-100 Solid Stains .013 - .015

Exterior House Paints .013 - .017 Interior Wall Paints .013 - .017 Interior & Exterior Primers .017 - .019

Heavy 30-60 Commercial Grade

Architectural Coatings .017 - .019 Interior Wall Paints .017 - .019 Interior Wall Primers .017 - .019 Dry Fall (quick dry) .019 - .023 One Coat, Primer-Finish Paints .019 - .023

Extra Heavy 0 Elastomerics .021 - .031

Pigmented Waterproofers .021 - .027 Block Filler .025 - .031

Orice sizes recommended on this chart are based on fan widths between 8 inches (20 cm) and 12 inches (30 cm)

PowrTwin Plus 9

Operation

Attention

4. Operation

This equipment produces a fluid stream at extremely high pressure. Read and understand the warnings in the Safety Precautions section at the front of this manual before operating this equipment.

4.1 Setup

1. Make sure the siphon hose (g. 4, 1) is connected to the uid section (2) and the bleed hose (3) is connected to the bleed valve (4). They each have factory installed PTFE tape on the male end of the hoses and should be wrench tight.

Piston Lube prevents increased wear and tear to the packings.

5. Check the hydraulic uid level daily before starting the sprayer. The hydraulic uid level should be at the “Full” mark on the dipstick. Refer to the Maintenance section of this manual for hydraulic system maintenance instructions.

Use of Titan’s Coolflo™ Hydraulic Fluid (P/N 430-361) is mandatory in the hydraulic system. Do not use any other hydraulic fluid. Use of any other hydraulic

Attention

fluid may seriously damage the hydraulic system and will void the warranty.

2. Attach a minimum of 15m of nylon airless spray hose to the sprayer. Do not use PTFE tape or thread sealant on the spray hose connection.

3. Attach an airless spray gun to the spray hose. Do not attach the tip to the spray gun yet. Remove the tip if it is already attached.

a. To use two guns, remove the plug from the second gun outlet

4. Fill the oil cup 1/2 full with Piston Lube (P/N 314-480). This

on the lter assembly. Connect a hose and gun to the outlet.

For multiple gun operation, connect a multiple gun

manifold to the single gun outlet. Connect a hose and gun to each outlet. Make sure the second gun outlet remains plugged. See “Technical Data”, Section 3.5 to determine number of guns and maximum spray tip sizes.

extends packing life.

6. For gas models, check the engine oil level daily before starting the sprayer. The gasoline engine oil level is determined by the engine manufacturer. Refer to the engine manufacturer’s service manual supplied with this sprayer.

7. For electric models, use a 20 amp service outlet. Always locate the electric model within 10 to 15 feet of the service

outlet. Use a short electric cable and a long paint hose. Any

extension cord will create some voltage drop. If an extension cord is necessary, use only a grounded 3-wire #12 extension cord.

8. Make sure the sprayer is earthed. All sprayers are equipped with a earthing lug. An earthing cable (not supplied) should be used to connect the sprayer to a true earth ground. Check your local electrical regulations for detailed earthing instructions.

Proper earthing is important. This applies to both gas and electric powered models. The passage of some materials through the nylon uid hose will build up a static electric charge, which if discharged, could ignite solvent vapors present and create an explosion.

9. Strain all paints with a nylon strainer to ensure trouble free operation and freedom from frequent cleaning of the inlet screen and gun lter.

10. Make sure the spray area is well ventilated to prevent hazardous operation with volatile solvents or exhaust fumes.

If lacquer or other flammable materials are to be sprayed, ALWAYS locate the sprayer outside the immediate spraying area. Failure to do so may cause an explosion.

11. Locate the sprayer outside the immediate spraying area to avoid clogged air intake of the engine or electric motor with overspray.

10 PowrTwin Plus

Operation

4.2 Preparing a New Sprayer

If this unit is new, it is shipped with test uid in the uid section to prevent corrosion during shipment and storage. This uid must be thoroughly cleaned out of the system with mineral spirits before you begin spraying.

Always keep the trigger lock on the spray gun in the locked position while preparing the system.

Attention

1. Place the siphon tube into a container of mineral spirits.

2. Place the bleed hose into a metal waste container.

3. Turn the pressure control knob fully counterclockwise to its lowest pressure setting (g 7, 1).

4. Open the hydraulic shut-o valve (2) located on the hydraulic pressure hose. The handle should be in line with the hose.

5. Open the bleed valve (3) by turning it fully counterclockwise.

9. Turn o the sprayer.

a. To turn o the gas engine,

• set the pressure to minimum by turning the pressure control

knob fully counterclockwise,

• move the throttle lever to the slow position, and

• turn the engine switch to the OFF position.

b. To turn o the electric motor,

• set the pressure to minimum by turning the pressure control

knob fully counterclockwise,

• move the ON/OFF switch to the OFF position.

6. Start the engine or turn on the electric motor.

a. To start the gas engine (g. 8),

• move the fuel valve lever (2) to the open position,

• move the throttle lever (3) to its middle point,

• move the choke lever (4) to the closed position for a cold

• turn the engine switch (1) to the ON position, and

• pull the starter rope (5) briskly until the engine starts.

b. To start the electric motor, move the ON/OFF switch to the ON

engine or to the open position for a warm engine,

position.

7. Turn the pressure control knob (g. 7, 1) clockwise approximately 1/3 of the way down to increase pressure until the sprayer cycles evenly and solvent ows freely from the bleed hose.

8. Allow the sprayer to run for 15–30 seconds to ush the test uid out through the bleed hose and into the waste container.

PowrTwin Plus 11

Operation

4.3 Preparing to Paint

Before painting, it is important to make sure that the uid in the system is compatible with the paint that is going to be used.

Incompatible uids and paint may cause the valves

Attention

1. Place the siphon tube into a container of the appropriate

2. Place the bleed hose into a metal waste container.

3. Turn the pressure control knob fully counterclockwise to its

4. Open the hydraulic shut-o valve (2) located on the hydraulic

5. Open the bleed valve (3) by turning it fully counterclockwise.

6. Start the engine or turn on the electric motor.

a. To start the gas engine (g. 8),

• move the fuel valve lever (2) to the open position,

• move the throttle lever (3) to its middle point,

• move the choke lever (4) to the closed position for a cold

• turn the engine switch (1) to the ON position, and

• pull the starter rope (5) briskly until the engine starts.

b. To start the electric motor, move the ON/OFF switch to the ON

7. Turn the pressure control knob (1) clockwise approximately

8. Allow the sprayer to run for 15–30 seconds to ush the test

9. Turn o the sprayer.

a. To turn o the gas engine,

• set the pressure to minimum by turning the pressure control

• move the throttle lever to the slow position, and

• turn the engine switch to the OFF position.

b. To turn o the electric motor,

• set the pressure to minimum by turning the pressure control

• move the ON/OFF switch to the OFF position.

to become stuck closed, which would require disassembly and cleaning of the sprayer’s uid section.

Always keep the trigger lock on the spray gun in the locked position while preparing the system.

solvent for the material being sprayed.

If you are spraying a water-based latex, ush with warm, clean water. If you are using any other material, check with the material manufacturer for a compatible solvent.

lowest pressure setting (g 7, 1).

pressure hose. The handle should be in line with the hose.

engine or to the open position for a warm engine,

position.

1/3 of the way down to increase pressure until the sprayer cycles evenly and solvent ows freely from the bleed hose.

uid out through the bleed hose and into the waste container.

knob fully counterclockwise,

Earth the gun by holding it against the edge of the metal container while flushing. Failure to do so may lead to a static electric discharge, which may cause a fire.

14. Trigger the gun into the metal waste container until the old solvent is gone and fresh solvent is coming out of the gun.

15. Lock the gun by turning the gun trigger lock to the locked position (g 10).

16. Set down the gun and increase the pressure by turning the pressure control knob slowly clockwise to its highest setting.

17. Check the entire system for leaks. If leaks occur, turn the sprayer o and follow the “Pressure Relief Procedure” in this manual before tightening any ttings or hoses.

18. Follow the “Pressure Relief Procedure” (section 4.5) in this manual before changing from solvent to paint.

Be sure to follow the Pressure Relief Procedure when shutting the unit down for any purpose, including servicing or adjusting any part of the spray system, changing or cleaning spray tips, or preparing for cleanup.

Make sure that the spray gun does not have a tip or tip guard installed.

10. Close the bleed valve by turning it fully clockwise.

11. Start the engine or turn on the electric motor.

12. Turn the pressure control knob clockwise approximately 1/3 of the way down to increase pressure.

13. Unlock the gun by turning the gun trigger lock to the

unlocked position.

12 PowrTwin Plus

Operation

4.4 Painting

1. Place the siphon hose into a container of paint.

2. Place the bleed hose into a metal waste container.

3. Turn the pressure control knob fully counterclockwise to its lowest pressure setting (g 7, 1).

4. Open the hydraulic shut-o valve (2) located on the hydraulic pressure hose. The handle should be in line with the hose.

5. Open the bleed valve (3) by turning it fully counterclockwise.

6. Start the engine or turn on the electric motor.

a. To start the gas engine (g. 8),

• move the fuel valve lever (2) to the open position,

• move the throttle lever (3) to its middle point,

• move the choke lever (4) to the closed position for a cold

engine or to the open position for a warm engine,

• turn the engine switch (1) to the ON position, and

• pull the starter rope (5) briskly until the engine starts.

b. To start the electric motor, move the ON/OFF switch to the ON

position.

7. Turn the pressure control knob (1) clockwise approximately 1/3 of the way down to increase pressure until the sprayer cycles evenly and solvent ows freely from the bleed hose.

8. Turn o the sprayer.

a. To turn o the gas engine,

• set the pressure to minimum by turning the pressure control

knob fully counterclockwise,

• move the throttle lever to the slow position, and

• turn the engine switch to the OFF position.

b. To turn o the electric motor,

• set the pressure to minimum by turning the pressure control

knob fully counterclockwise,

• move the ON/OFF switch to the OFF position.

9. Remove the bleed hose from the waste container and place it into the container of paint.

10. Close the bleed valve by turning it fully clockwise.

11. Start the engine or turn on the electric motor.

12. Turn the pressure control knob clockwise approximately 1/3 of the way down to increase pressure.

13. Unlock the gun by turning the gun trigger lock to the

unlocked position.

Earth the gun by holding it against the edge of the metal container while flushing. Failure to do so may lead to a static electric discharge, which may cause a fire.

19. Increase the pressure by turning the pressure control knob slowly clockwise and test the spray pattern on a piece of cardboard. Adjust the pressure control knob until the spray from the gun is completely atomized.

Turning the pressure up higher than needed to

atomize the paint will cause premature tip wear and additional overspray.

4.5 Pressure Relief Procedure

1. Lock the spray gun by turning the gun trigger lock to the locked position.

2. Turn o the sprayer.

a. To turn o the gas engine,

• set the pressure to minimum by turning the pressure control

• move the throttle lever to the slow position, and

• turn the engine switch to the OFF position.

b. To turn o the electric motor,

• set the pressure to minimum by turning the pressure control

• move the ON/OFF switch to the OFF position.

3. Close the hydraulic shut-o valve on the hydraulic pressure

4. Unlock the gun by turning the gun trigger lock to the

5. Hold the metal part of the gun rmly to the side of a metal

6. Trigger the gun to remove any pressure that may still be in the

7. Lock the gun by turning the gun trigger lock to the locked

8. Place the bleed hose into the metal waste container.

9. Open the bleed valve by turning it fully counterclockwise.

knob fully counterclockwise,

hose.

unlocked position.

waste container to earth the gun and avoid a build up of static electricity.

hose.

position.

14. Trigger the gun into the metal waste container until all air and solvent is ushed from the spray hose and paint is owing freely from the gun.

15. Lock the gun by turning the gun trigger lock to the locked position (g 10).

16. Turn o the sprayer.

17. Attach tip guard and tip to the gun as instructed by the tip guard or tip manuals.

POSSIBLE INJECTION HAZARD. Do not spray without the tip guard in place. Never trigger the gun unless the tip is in either the spray or the unclog position. Always engage the gun trigger lock before removing, replacing or cleaning tip.

18. Start the engine or turn on the electric motor.

PowrTwin Plus 13

Cleanup

5. Cleanup

12. Start the engine or turn on the electric motor.

The sprayer, hose, and gun should be cleaned thoroughly after daily use. Failure to do so permits material to build up, seriously aecting the

Attention

performance of the unit.

Always spray at minimum pressure with the gun nozzle tip removed when using mineral spirits or any other solvent to clean the sprayer, hose, or gun. Static electricity buildup may result in a re or explosion in the presence of ammable vapors.

5.1 Special cleanup instructions for use with

ammable solvents

• Always ush spray gun preferably outside and at least one hose

• If collecting ushed solvents in a one gallon metal container,

• Area must be free of ammable vapors.

• Follow all cleanup instructions.

length from spray pump.

place it into an empty ve gallon container, then ush solvents.

5.2 Cleaning the sprayer

1. Follow the “Pressure Relief Procedure” found in the Operation section of this manual, section 4.5.

2. Remove the gun tip and tip guard and clean with a brush using the appropriate solvent.

3. Place the siphon tube into a container of the appropriate solvent.

Earth the gun by holding it against the edge of the metal container while flushing. Failure to do so may lead to a static electric discharge, which may cause a fire.

13. Trigger the gun into the metal waste container until the paint is ushed out of the hose and solvent is coming out of the gun.

14. Continue to trigger the spray gun into the waste container until the solvent coming out of the gun is clean.

For long-term or cold weather storage, pump mineral sprits through the entire system.

15. Follow the “Pressure Relief Procedure” found in the Operation section of this manual.

16. Store the sprayer in a clean, dry area.

Do not store the sprayer under pressure.

Attention

5.3 Cleaning a Clogged Tip

1. Follow the “Pressure Relief Procedure” in the Operation section of this manual.

2. If the tip clogs, rotate the tip handle 180° until the arrow on the handle is facing the opposite of the spray direction and the handle clicks in the reverse position.

Use only compatible solvents when cleaning out oil based enamels, lacquers, coal tar, and epoxies. Check with the uid manufacturer for the

Attention

4. Place the bleed hose into a metal waste container.

5. Set the pressure to minimum by turning the pressure control

6. Open the hydraulic shut-o valve located on the hydraulic

7. Open the bleed valve (3) by rotating the bleed valve handle

recommended solvent.

knob (1) fully counterclockwise.

pressure hose (2). The handle should be in line with the hose.

fully counterclockwise.

3. Trigger the gun once so that the pressure can blow the clog

out. NEVER use the tip in the reverse position for more than ONE trigger pull at a time. This procedure can be repeated

until the tip is free of clogging.

The flow from the spray tip is at very high pressure. Contact with any body part may be dangerous. Do not place finger on gun outlet. Do not point the gun at any person. Never operate the spray gun without the proper tip guard.

8. Start the engine or turn on the electric motor.

9. Allow the solvent to circulate through the sprayer and ush the paint out of the bleed hose into the metal waste container.

10. Turn o the sprayer.

11. Close the bleed valve by rotating the bleed valve handle fully clockwise.

14 PowrTwin Plus

Maintenance

6. Maintenance

Before proceeding, follow the Pressure Relief Procedure outlined previously in this manual. Additionally, follow all other warnings to reduce the risk of an injection injury, injury from moving parts or electric shock. Always unplug the sprayer before servicing!

6.1 Daily Maintenance

Two daily procedures are required for routine operator maintenance on this sprayer:

A. Lubricating the upper packings. B. Cleaning the lter screen

A) Lubricating the Upper Packings

1. Clean out the paint that has seeped past the upper packings into the packing oil reservoir (g. 13, item 1) above the uid section.

2. Fill the packing oil reservoir 1/2 full with Piston Lube (P/N 314-

480) supplied by the factory. This will extend packing life.

6.2 Maintaining the Filter Assembly

Clean the lter regularly. Dirty or clogged lters can greatly reduce ltering ability and cause a number of system problems including poor spray patterns, clogged spray tips, etc.

Cleaning (Fig. 15)

To clean the lter, perform the following procedure.

1. Follow the “Pressure Relief Procedure” found in the Operation section of this manual.

2. Remove the lter cap assembly (1) and spring (2).

3. Pull the lter element with ball straight (3) out of the lter body (4).

4. Clean inside the lter body, lter element with ball, and lter cap assembly using the appropriate solvent.

Use care in handling parts as dirt, debris, scratches,

or nicks may prevent o-rings or gaskets from sealing. This lter element lters from the inside out. Be sure

to clean the lter element thoroughly on the inside. Soak in solvent to loosen hardened paint or replace.

Do not over-ll the reservoir so that it overows and drips into the paint.

B) Cleaning the Filter Screen

1. The lter screen will clog and must be cleaned at least once a day.

2. Loosen the hex nut (g. 14, item 1) that secures the lter screen to the siphon tube.

3. Remove the lter screen (2) from the bottom of the siphon tube.

4. Clean thoroughly with the appropriate solvent.

5 6

Inspection (Fig. 15)

Inspect all parts of the lter assembly before reassembly.

1. Inspect the ball inside the lter element. If the ball has pressure cuts or scratches, replace the lter element.

a. If the ball is cut, remove the PTFE o-ring (5) using an o-ring pick

and remove the carbide seat (6).

b. Check the seat for nicks or grooves. If the seat is damaged,

replace.

Removal of the PTFE o-ring will damage the o-ring and require replacement.

1 2

PowrTwin Plus 15

2. Remove the spring (2) from the spring guide on the lter cap.

a. Measure the length of the spring uncompressed. If it measures

less than 3/4” from end to end, replace.

b. Push the spring back onto the spring guide until it “snaps” back

into position.

3. Inspect the two PTFE gaskets (7,8) and the PTFE o-ring (5) for deformity, nicks, or cuts. Replace, if needed.

The PTFE gaskets, PTFE o-ring, and spring are packaged in Filter Service Kit P/N 930-050.

Maintenance

Reassembly (Fig. 15)

After cleaning and inspecting all parts, reassemble the lter.

1. Place the carbide seat (6) into the lter body (4). Make sure the beveled side of the seat is facing up.

2. Place the PTFE o-ring (5) into the groove on the outer diameter of the carbide seat (6).

3. Place the lter element with ball (3) into the lter body (4).

The top and bottom of the lter element with ball are identical.

4. Push the spring (2) back onto the spring guide of the lter cap (1) until it “snaps” back into position, if not already done.

5. Place the thin PTFE gasket (8) onto the step at the top of the lter body (4).

6. Place the thick PTFE gasket (7) onto the top of the thin gasket (8).

7. Tighten the lter cap assembly (1) onto the lter body (4).

2 3

5 6

16 PowrTwin Plus

Maintenance

6.3 Maintaining the Hydraulic System

Use of Titan’s Coolflo™ Hydraulic Fluid is mandatory in the PowrTwin Plus hydraulic system. Do not use any other hydraulic fluid. Use of any other hydraulic

Attention

1. Check the hydraulic uid daily. It should be at the “Full”

fluid may seriously damage the hydraulic system and will void the warranty.

mark (g. 16, item 1) on the dipstick (2). If it is low, add only

Titan Coolo™ Hydraulic Fluid (P/N 430-361). Never add

or change hydraulic uid except in a clean, dust-free area. Contamination of the hydraulic uid will shorten hydraulic pump life and may void warranty.

2. Change the hydraulic uid every twelve months. Drain the old uid from the tank and ll with 6.25 quarts of hydraulic uid. Start the sprayer at just enough pressure to operate the uid section. Run the sprayer at this low pressure for at least 5 minutes. This removes air from the system. Check the uid level after this procedure. Do not over-ll.

When replacing the hydraulic filter (3) during a

3. The hydraulic system has an external, replaceable hydraulic

4. The hydraulic pump should not be serviced in the eld. If

6.4 Maintaining the Fluid Section

If the sprayer is going to be out of service for an extended period of time, it is recommended that following cleanup, a kerosene and oil mixture be introduced as a preservative. Packings may tend to dry out from lack of use. This is particularly true of the upper packing

set for which upper packing lubricant Piston Lube (P/N 314-480) is

recommended in normal usage. If the sprayer has been out of service for an extended period of time,

it may be necessary to prime the pump with solvent. It is extremely important that the threads on the siphon hose coupling are properly sealed. Any air leakage will produce erratic operation of the sprayer and may damage the system. The up and the down strokes should be approximately equal in time (one should not be faster than the other). A fast up or down stroke may indicate air in the system or malfunctioning valve or seats (see the Troubleshooting section).

fluid change, it may be necessary to add up to one additional quart of hydraulic fluid.

lter. Change the lter every twelve months.

service on the hydraulic pump is required, it must be returned to Titan.

6.5 Basic Engine Maintenance (gas engine)

• For detailed engine maintenance and technical specications

refer to the separate gasoline engine manual.

• All service to the engine should be performed by a dealer

authorized by the engine manufacturer.

• Use a premium quality motor oil. 10W30 is recommended for

general all temperature use. Other viscosities may be required in other climates.

• Use only a (NGK) BR-6HS (PT4900), or (NGK) BP6ES / BPR6E

spark plug (PT6900/PT8900/PT12000). Gap the plug to 0.028 to 0.031 In. (0.7 to 0.8 mm) Always use a spark plug wrench.

Daily

1. Check engine oil level, and ll as necessary.

2. Check gasoline level, and ll as necessary.

Always follow the fueling procedure outlined earlier in this manual.

First 20 Hours

1. Change engine oil.

Every 100 Hours

1. Change engine oil.

2. Clean the sediment cup.

3. Clean and re-gap the spark plug.

4. Clean the spark arrestor.

Weekly

1. Remove the air lter cover and clean the element. In very dusty environments, check the lter daily. Replace the element as needed. Replacement elements can be purchased from your local engine manufacturer dealer.

Engine Operation and Service

1. Clean and oil air lter pad on gasoline engine every 25 hours or once weekly. Do not permit the air intake screen around the y wheel of the gas engine to load up with paint or trash. Clean it regularly. The service life and eciency of the gas engine model depends upon keeping the gasoline engine running properly. Change the oil in the engine every 100 hours. Failure to observe this may result in engine overheating. Consult the engine manufacturer’s service manual provided.

2. To conserve fuel, service life, and eciency of the sprayer, always operate the gasoline engine at the lowest RPM at which it runs smoothly without laboring and delivers the amount required for the particular painting operation. Higher RPM does not produce higher working pressure. The gasoline engine is connected to the hydraulic pump by a pulley combination designed to produce full paint delivery at maximum RPM.

3. The warranty on gasoline engines or electric motors is limited to the original manufacturer.

PowrTwin Plus 17

Maintenance

6.6 Replacing the Motor Brushes (optional 120V electric motor)

The 120V electric Convertokit is available for separate purchase.

Perform this procedure using Motor Brush Kit P/N 978-050. The kit

consists of two brushes, two springs, and two clips.

Brushes should be replaced when they are worn to

1. Remove both inspection covers (1) on the motor.

less than 1/2 inch. Check and replace both brushes at the same time.

2. Push in the spring clip (2) to unhook it, then pull it out.

3. Loosen the terminal screw (3). Pull the brush lead (4) away,

but leave the motor lead in place. Remove the brush and spring.

7. Reinstall both inspection covers.

If electric motor overloads and stops running, IMMEDIATELY turn the motor off and follow the Pressure Relief Procedure in the Cleanup section of this manual. Wait until the motor cools (approximately 30 minutes). Then push in the bubble top, manual reset button, turn the motor on and pressurize the system.

9 2

4. Inspect the commutator (5) for burning, excessive pitting or

gouging. A black color on the commutator is normal.

5. Install the new brush (6) so its lead slides in the long slot of the

brush holder (7). Push the terminal under the terminal screw washer (8). Ensure the motor lead is still connected at the screw. Tighten the screw.

6. Place the spring (9) on the brush (6) as shown above. Push

in and hook the spring clip (2). Repeat this procedure for the other side.

18 PowrTwin Plus

Attention

Maintenance

6.7 Replacing the Belt (Fig. 21)

Before replacing the belt on your unit, make sure you have performed the “Pressure Relief Procedure” as illustrated in the Operation section of this manual. DO NOT attempt this repair while the unit is running.

The graphics below show a unit with a gas engine. All instructions given in this section will apply to

both gas engine models and electric motor models except where noted.

1. Loosen the bolt (1) on the front of the belt guard. Lift open

the front end of the belt guard (2) so that the front end of the belt (3) is exposed.

2. Gently lift the front end of the gas engine / electric motor.

This will loosen the tension on the belt and make it easier to remove.

PINCH HAZARD. Make sure your fingers remain clear of the gas engine / electric motor mounting plate.

BURN HAZARD. Make sure the gas engine has had time to sufficiently cool before touching it.

3. While the gas engine / electric motor is lifted up, remove the belt from the front (4) and rear (5) pulleys.

4. Install the new belt:

a. Insert the belt into the xed section of the belt guard (6). Loop

the belt over the rear pulley (5) until the belt engages the

pulley groove. b. Gently lift the front end of the gas engine / electric motor. c. With the front end of the gas engine / electric motor lifted, loop

the other end of the belt around the front pulley (4). d. Gently set the the gas engine / electric motor down. The

weight of the gas engine / electric motor will create tension in

the belt and prevent it from coming o.

Make sure the belt is not pinched or twisted in any way once you have set the gas engine / electric motor back into place.

e. Close the belt guard (2) and tighten the belt guard bolt (1).

5 6

PowrTwin Plus 19

Maintenance

6.8 Servicing the Hydraulic Motor (Fig. 22)

1 2

4 5

6 7

(A)

(B)

28 29

Refer to the ”SAE O-Ring Fitting Installation”

Perform this procedure using the necessary parts from Motor Service

Kit — Minor (P/N 235-050). If the hydraulic motor is operable, start

the machine and jog the piston rod (19) into its top position.

procedure at the end of this section for installation instructions for item 22.

Servicing of the hydraulic motor should be carried out in a clean, dust free area only. Any dust or metallic particles left in the motor or entering it on reassembly may damage the critical parts and aect its service life and warranty. All parts should be inspected for absolute cleanliness.

Disassembling the Hydraulic Motor

1. Disconnect the pressure hose assembly (B) from the elbow (34 and 35 in Hydraulic System parts list) on the back of the hydraulic pump.

2. Remove the two mounting screws and two lock washers (17 and 16, in Cart Assembly parts list) that attach the motor/ pump assembly to the cart.

3. Place the motor/pump assembly in a vise, holding it securely by the motor/pump block (31).

4. Remove cylinder head plug (1).

5. Loosen lock ring (28) with a spanner wrench and unthread tube retaining nut on tee (24). Loosen tube retaining nut on elbow (22). Slide the nut down. Push motor tube (23) into tee (24) far enough to clear elbow (22). Slowly unthread cylinder head (8) and Iift it just high enough above the cylinder (29) to reach the valve rod assembly (18) with vise grip pliers.

6. The piston rod (19) should be near the top of its stroke for disassembly. It may be necessary to use a wood or nylon driver to push the piston rod up to its top position.

7. Grip the valve rod securely with vise grip pliers and then remove the FlexLoc nut (3) from the top of the valve rod assembly (18). Be careful that spool (10) does not fall. The

cylinder head (8) can now be lifted o. Unthread the cylinder

(29) from the motor/pump block (31).

An extra lock ring (28) can be used to jam the two

8. To remove the connecting pin (Fig. 23, 1), slide the retaining

lock rings together on the cylinder and a pipe wrench can be used to unthread the cylinder (29) from the motor/pump block.

ring (2) down with a small screwdriver, and then push the connecting pin out.

9. Remove the piston rod assembly from the motor/pump block (31).

10. Remove rod seal (30), being extremely careful not to scratch the seal groove in the motor/pump block (31).

11. Place the piston retainer screw (14) on the piston rod assembly in a vise. Slide a long bar through the hole at the base of the piston rod for leverage, and unthread the piston rod from the piston retainer screw.

12. Remove piston (19) and lift out valve rod assembly (18).

20 PowrTwin Plus

Attention

Maintenance

13. Remove piston seal (16) and o-ring (17).

14. Remove trip retainers (4), trip springs (6), and balls (7) from cylinder head (8). Remove o-rings (5) from trip retainers.

15. Remove retaining ring (13) and sleeve retainer (12). Gently tap spool/sleeve set (10) out of cylinder head (8) using a wood or nylon rod.

16. Inspect piston rod (19) and cylinder (29) for wear, scratches, and dents. Replace if damaged.

17. Inspect spool valve (10) for wear. Replace if necessary. spool valve should move smoothly and freely with no force by holding in a vertical position. If it does not, it can cause the motor to stall.

Reassembling the Hydraulic Motor

1. Separate spool/sleeve set (10). Place o-rings (11) onto sleeve. Lubricate o-rings with hydraulic oil. Gently push the sleeve into cylinder head (8) with the atter side of the sleeve facing

out. Use a nylon rod to tap sleeve down until it reaches its full

depth. Do not use any other type of tool that might damage or leave particles or residue on the sleeve. Install the spool through the top of the cylinder head, down into the sleeve.

Do not use Piston Lube pump packing lubricant. It is a solvent and will severely damage seals and O-Rings of the hydraulic motor.

2. Install o-rings (5) on trip retainers (4). Install trip retainer balls (7) followed by springs (6) which, when installed, will hold spool/sleeve set (10) in proper place for assembly.

3. Install sleeve retainer (12) followed by retainer ring (13) into cylinder head (8), which will hold valve sleeve in place. Install o-ring (9) in the o-ring groove of the cylinder head.

4. Replace rod seal (30) in motor/pump block (31). Be sure the open portion of the seal is facing upward (V). This seal requires no special tool.

5. Place piston rod (19) in vise. Inspect valve rod assembly (18) for any damage. Make sure the lock nut at the bottom of the

valve rod assembly is secure. DO NOT remove. Then, place into

piston rod as illustrated. Install o-ring (17), lubricating it well and replacing piston (15) onto piston rod (19). Put one drop of blue Loctite on the piston retainer screw (14). Tighten piston retainer screw until piston is locked into place. Check valve rod assembly for normal spring action at this time.

6. Install piston seal (16) with lips facing downward. Carefully install o-ring (17). Expand the ring and stretch it suciently for installation.

7. With motor/pump block (31) still in vise, install rod seal (30) by pushing it towards its groove with a properly sized blunt

rod. Then complete installation with the ngers. No tool is

necessary. Do not twist the seal.

8. Pre-lubricate the piston and valve rod assembly with Coolo™

hydraulic uid (P/N 430-361). Install piston rod (19) into

motor/pump block (31) with a gently pushing and rotating motion to work the piston rod in through the rod seal (30).

rod pass through the top of the spool/sleeve set (10). The valve rod threads must be clean and free of oil. Place one drop of blue Loctite on threads of ex lock nut (3) and thread nut onto valve rod to full tight position (do not over-tighten) while holding valve rod below with vise grip pliers.

13. Thread cylinder head (8) down onto the cylinder (29) and then back o just enough to reassemble hydraulic ttings and motor tube (23). Tighten lock ring with spanner wrench to hold cylinder head in position.

14. The tee assembly (24) and the elbow (22) use an o-ring (25) to seal on the outer diameter (O.D.) of the motor tube (23). The O.D. of the motor tube should be free of scratches or sharp edges. The lock nuts on these ttings rst should be hand tightened, then wrench tightened another half turn.

15. Install o-ring (2) onto cylinder head plug (1). Tighten.

Hydraulic Motor Cut-Away

Torque ex locknut to

40 in./lbs. (4.5 Nm).

Use blue Loctite.

Use blue

Loctite on

lock ring.

Use

hydraulic

sealant.

Torque head plug to 15 ft./lbs. (22 Nm). Do not over-tighten o-ring seal.

Torque trip retainers to 8 ft./lbs. (10.8 Nm). Do not over-tighten o-ring seal.

Torque piston retainers to 40 ft./lbs. (55 Nm). Use red Loctite.

Seal lip must face down.

Inspect the bottom of piston rod (19) for nicks or sharp areas that could damage the piston seal during

installation through the motor/pump block (31).

9. Replace the connecting rod pin and retainer ring.

10. Install o-ring (9) on cylinder wall. Lubricate ring and inner wall. With the piston rod held rmly, the cylinder should be gently driven over the piston seal with a rubber mallet. Tightly thread the cylinder into motor/pump block (31).

11. Raise piston rod (19) to top position and thread lock ring (28) all the way up on upper threads of cylinder (29).

12. Pull valve rod assembly (18) up as far as it will travel and grasp it with vise grip pliers. Then install cylinder head (8), already assembled, over valve rod until the top threads of the valve

PowrTwin Plus 21

Seal lip must

face up.

Valve rod assembly is factory set and permanently Loctited. Do not disassemble.

Maintenance

6.9 Servicing the Fluid Section

PT4900 Plus PT6900 Plus / PT8900 Plus / PT12000 Plus

1 2

10 11 12

3 21

17 18 19

1 2

9 10

11 12

16 17

18 19 20

Attention

Use of non-Titan service parts may void warranty. Ask for original parts made by Titan for best services. This pump should receive a routine servicing after approximately 1,000 hours of use. Earlier servicing is required if there is excessive leakage from the top packing or if pump strokes become faster on one stroke or the other. The use of Titan Piston Lube (P/N 314-480) is recommended as an upper packing lubricant. Do not substitute oil, water, or solvent for an upper packing lubricant.

Numbers in parentheses refer to the item numbers in the fluid section illustrations. If there are two numbers, the first number represents the item number for the PT4900 Plus and the second number represents the item number for the PT6900 Plus / PT8900 Plus / PT12000 Plus.

Disassembling the Fluid Section

1. Remove the siphon hose assembly. Unthread the foot valve

housing (20,21) and the pump cylinder (14) with a strap wrench.

2. Slide the retainer ring (1) up with a small screwdriver, then push the connecting pin (2) out.

3. Pull the displacement rod (6) through the lower cavity of the motor/pump block.

4. Remove the PTFE o-ring (3), upper packing spring (5), and upper packing set (4) from the motor/pump block.

5. Hold the displacement rod (6) in a vise by the ats at the top of the displacement rod and remove the outlet valve housing (13) with a wrench while holding the displacement rod horizontal with wooden support, if necessary. Remove the seal washer (12), outlet valve seat (11), outlet valve ball (10), outlet valve cage (9, PT6900/PT8900/PT12000) lower packing set (4), lower packing spring (9,8), sleeve (8, PT4900 only), and spring retainer (7).

6. Using a 1/2” extension bar attached to a 1/2” drive ratchet,

insert the end of the extension bar into the square opening of the foot valve cage (16,17) inside the foot valve housing

(20,21). Unscrew and remove the foot valve cage along with

the wave washer (21,16) from the foot valve housing.

7. Remove the PTFE o-ring (3), foot valve ball (17,18), foot valve seat (18,19), and seat o-ring (19,20) from the foot valve housing (20,21).

8. Remove the o-ring (15) from the pump cylinder (14)

22 PowrTwin Plus

Maintenance

Reassembling the Fluid Section

Use PTFE tape on all threaded pipe connections.

1. Place a new seat o-ring (19,20) into the groove in the bottom of the foot valve housing (20,21).

2. Inspect the foot valve seat (18,19) for wear. If one side is worn, ip the seat to the unused side. If both sides are worn, install a new seat. Place the new or ipped seat (worn side down) into the bore at the bottom of the foot valve housing (20,21).

3. Place a new foot valve ball (17,18) onto the foot valve seat

(18,19). Using a 1/2” extension bar attached to a 1/2” drive

ratchet, insert the end of the extension bar into the square opening of the foot valve cage (16,17) and screw the foot valve cage into the foot valve housing (20,21). Torque the cage to 240 in./lbs. (20 ft./lbs.).

4. Place the wave washer (21, 16) on top of the foot valve cage (16,17).

5. Insert a new PTFE o-ring (3) into the groove of the foot valve housing (20,21). Lubricate the o-ring using oil or grease.

6. After soaking the leather packings in oil (preferably linseed oil), reassemble the lower packing set (4). Place the set onto the outlet valve housing (13) with the peak of the “V” packings pointing down toward the hex on the outlet valve housing.

All leather packings must be soaked in CoolFlo hydraulic oil for 15–20 minutes before installation.

Soaking the packings too long will cause the packings to swell and create diculty during reassembly.

It is not necessary to over-tighten the foot valve

housing. O-ring seals perform sealing function without excessive tightening. Full thread engagement is sufficient. The foot valve housing may be rotated backward up to 1/2 turn from full engagement for convenient hose position.

For siphon hose attachment, it is critically important that the threads of the siphon hose fit snugly into the foot valve housing with the hose assembly couplings PTFE taped and sealed to prevent air leakage.

Fluid Section Cut-Away

Peaks of upper packings must

face up.

Oil cup area for piston lube packing lubricant.

7. Inspect the outlet valve seat (11) for wear. If one side is worn, ip the seat to the unused side. If both sides are worn, use a new seat. Insert the outlet valve cage (9, PT6900/PT8900/ PT12000) outlet valve ball (10), new or ipped seat (worn side away from ball), and a new seal washer (12) into the displacement rod (6).

8. Clean the threads on the outlet valve housing (13) and coat the threads with blue Loctite #242. Make sure the Loctite is only on the threads.

9. Place the lower packing spring (9,8) onto the outlet valve housing (13) followed by the sleeve (8, PT4900 only) and spring retainer (7).

10. Screw the displacement rod (6) and the outlet valve housing (13) together. Tighten in a vise to 600 in./lbs. (50 ft./lbs.).

11. Insert the PTFE o-ring (3) into the upper grove of the motor/ pump block.

12. Insert the upper packing set (4) into the motor/pump block with the peak of the “V” packings pointing up toward the motor.

The packings must be soaked in CoolFlo hydraulic oil before installation.

13. Place the upper packing spring (5) into the motor/pump block with the small tapered end facing up toward the motor/pump block.

14. Insert the displacement rod (6) up through the upper packings in the motor/pump block.

15. Align the holes in the displacement rod (6) and the hydraulic piston rod and insert the connecting pin (2). Replace the retaining ring (1) over the connecting pin.

16. Thread the short threads of the pump cylinder (14) into the motor/pump block and tighten with a strap wrench.

17. Place the o-ring (15) onto the top grove of the pump cylinder (14).

18. Thread the foot valve housing (20,21) onto the pump cylinder (14), tighten with a strap wrench and then back o to align the siphon hose.

Torque outlet

valve housing

to 50 ft./lbs.

(68 Nm).

Use blue

Loctite.

Peaks of lower packings must face down.

Lubricate O-ring.

PowrTwin Plus 23

Maintenance

6.10 SAE O-Ring Fitting Installation

1. Pull washer and o-ring back as far as possible.

2. Lubricate o-ring (1) and entrance port (2).

3. Screw tting in until washer pushes o-ring into entrance and

sits at against port. (Do not tighten! - only do this step hand tight to compress o-ring into port!)

4. Back tting out no more than one complete turn to align as required.

5. Torque nut wrench tight holding backup on tting (3). This should expose a recess gap (4) behind the nut which can act as an indicator that the tting is assembled correctly. (This is a feature for a specic version of this tting only - which screws into the cylinder head. Other ttings, as the ones which attach to the hydraulic pump, assemble the same but may not have the indicator.)

Avoid screwing in the fitting too far. This can cause the washer to bend, which will cause the O-ring to

Attention

24 PowrTwin Plus

extrude.

Avoid leaving the fitting out too far. This can lead to the O-ring being cut on the threads of the fitting.

Troubleshooting

7. Troubleshooting

7.1 Airless Gun

Problem

A. Spitting gun

B. Gun will not shut o

C. Gun does not spray

7.2 Fluid Section

Problem

A. Pump delivers on upstroke only

or goes up slowly and down fast (commonly called downstroke dive)

B. Pump delivers on down stroke

only or goes up fast and down slowly

C. Pump moves up and down fast,

delivering material

D. Pump moves up and down

slowly when spray gun is shut o

E. Not enough uid pressure at

gun

F. Pump chatters on up or down

stroke

Cause

1. Air in system

2. Dirty gun

3. Needle assembly out of adjustment

4. Broken or chipped seat

1. Worn or broken needle & seat

2. Needle assembly out of adjustment

3. Dirty gun

1. No paint

2. Plugged lter or tip

3. Broken needle in gun

Cause

1. Lower foot valve ball is not seating due to trash or wear

2. Material too viscous to siphon.

3. Air leaking in on siphon side or damaged siphon hose. Siphon may be too small for heavy material.

1. Upper ball is not seating due to trash or wear

2. Lower packing set is worn

1. Material container is empty or material is too thick to ow through siphon hose

2. Bottom ball stuck to foot valve seat

3. Siphon hose is kinked or loose

1. Loose connections. Bleed valve is open partially or bleed valve is worn. Lower packing seat is worn.

2. Upper and/or lower ball not seating

1. Spray tip is worn

2. Outlet lter or gun lter is clogged

3. Low voltage and/or inadequate amperage

4. Hose size or length is too small or too long

1. Solvent has caused upper packing to swell

Solution

1. Inspect connections for air leaks.

2. Disassemble and clean.

3. Inspect and adjust.

4. Inspect and replace.

1. Replace.

2. Adjust.

3. Clean.

1. Check uid supply.

2. Clean.

3. Replace.

Solution

1. Remove foot valve assembly. Clean and inspect. Test foot valve by lling with water; if ball fails to seal the seat, replace ball.

2. Thin material — contact manufacturer for proper

thinning procedures.

3. Tighten all connections between pump and paint container. If damaged, replace. Switch to larger diameter siphon set.

1. Check upper seat and ball with water. If ball fails to seal, replace seat.

2. Replace packing set if worn.

1. Rell with new material. If too thick, remove siphon hose, immerse uid section in material, and start pump to prime. Add thinner to material. Change to bigger siphon set. Open bleed valve to remove air and restart pump.

2. Remove foot valve. Clean ball and seat.

3. Straighten.

1. Check all connections between pump and gun. Tighten as necessary. If material is owing from bleed hose, close bleed valve or replace, if necessary. Should none of the above be evident, replace lower packing.

2. Reseat balls by cleaning.

1. Replace.

2. Clean or replace lter.

3. Check electrical service. Correct as required.

4. Increase hose size to minimize pressure drop through hose and/or reduce hose length.

1. Replace packing.

PowrTwin Plus 25

Troubleshooting

7.3 Hydraulic Motors

Problem

A. Oil motor stalls at bottom (no

unusual heat problems)

B. Oil motor stalls at top (no

unusual heat problems)

C. Low pressure (okay on down

stroke, sluggish on up.stroke —

high heat)

Note: Engine labors on upstroke, idles

back at stall on the down stroke.

D. Low pressure (both strokes -

high heat)

Note: Engine labors at stall on both

strokes.

Cause

1. Fluid pump piston seat unthreaded

2. Valve sticking or oil motor trip rod shifter assembly separated

1. Valve sticking

2. Broken spring retainer (valve rod assembly)

3. Broken spring or valve rod

4. Air in hydraulic motor

5. Air in uid pump

1. Blown piston seal

2. Cracked piston

1. Blown center o-rings on spool valve

2. Bad hydraulic pump

Solution

1. If connecting rod is okay, remove cylinder head plug and pop valve down. Replace plug and start machine. If machine cycles up and stops at bottom again, then problem is piston seat on uid pump. Check piston seat. Repair or replace as necessary. If piston seat is okay and problem does not change, check oil motor.

2. Remove valve and check for scratches and rough movement when sliding it up and down. Replace valve and spool in this condition. Check trip rod for possible separation.and spool in this condition. Check trip rod for possible separation.

1. Remove valve and check for scratches and rough movement when sliding it up and down. Replace valve and spool in this condition.

2. Replace valve rod assembly.

3. Replace valve rod assembly.

4. Reset valve. Purge Air, generally accomplished by low pressure cycling of motor/pump assembly for 5–10 minutes. Check for causes of air introduction:

• Loose ttings in tank.

• Loose ttings on hydraulic pump.

• Loose hose connections.

• Low oil in reservoir.

5. Stall at top can occur randomly when uid pump picks up air. Reset valve. Avoid air in the uid pump.

1. Before dismantling oil motor, start machine. With pump cycling under pressure, touch the hydraulic cylinder and the head to see if cylinder or head gets hotter. This will help determine if piston seal is blown or piston nut is broken. If heat is on the head, check the o-rings on spool valve.

2. Dismantle oil motor and check piston seals cylinder bore and piston nut. Pay special attention to piston nut. It can be cracked and not show externally.

1. Before dismantling oil motor, start machine. With pump cycling under pressure, touch the head to see if the head becomes hotter. This will help determine if center o-ring is blown on spool valve. If hot, remove and replace o-ring.

2. Replace hydraulic pump.

26 PowrTwin Plus

Troubleshooting

7.4 Spray Patterns

Problem

A. Tails

B. Hour glass

C. Distorted

D. Pattern expanding and

contracting (surge)

Cause

1. Inadequate uid delivery

1. Plugged or worn nozzle tip

1. Suction leak

2. Pulsating uid delivery

Solution

1. Fluid not atomizing correctly:

Increase uid pressure. Change to smaller tip orice size.

Reduce uid viscosity. Reduce hose length. Clean gun and lter(s). Reduce number of guns using pump.

1. Same as above.

1. Clean or replace nozzle tip.

1. Inspect for suction hose leak.

2. Change to a smaller tip orice size. Install pulsation dampener in system or drain existing one. Reduce number of guns using pump. Remove restrictions in system; clean tip screen if lter is used.

E. Round pattern

1. Worn tip

2. Fluid too heavy for tip

1. Replace tip.

2. Increase pressure. Thin material. Change nozzle tip.

PowrTwin Plus 27

Übersetzung der Originalbetriebsanleitung

Warnung!

Achtung: Verletzungsgefahr durch Injektion!

Airless-Geräte entwickeln extrem hohe Spritzdrücke.

Niemals Finger, Hände oder andere Körperteile mit dem Spritzstrahl in Berührung bringen!

Nie die Spritzpistole auf sich, Personen und Tiere richten. Nie die Spritzpistole ohne Spritzstrahl-Berührungsschutz

benutzen. Behandeln Sie eine Spritzverletzung nicht als harmlose Schnittver-

letzung. Bei einer Hautverletzung durch Beschichtungssto oder Lösemittel sofort einen Arzt aufsuchen zur schnellen, fachkundigen Behandlung. Informieren Sie den Arzt über den verwendeten Beschichtungssto oder das Lösemittel.

Vor jeder Inbetriebnahme sind gemäß Betriebsanleitung folgende Punkte zu beachten:

1. Fehlerhafte Geräte dürfen nicht benutzt werden.

2. Titan-Spritzpistole sichern mit Sicherungshebel am Abzugsbügel.

3. Erdung sicherstellen.

4. Zulässigen Betriebsdruck von Hochdruckschlauch und Spritzpistole überprüfen.

5. Alle Verbindungsteile auf Dichtheit prüfen.

Anweisungen zur regelmäßigen Reinigung und Wartung des Gerätes sind streng einzuhalten.

Vor allen Arbeiten am Gerät und bei jeder Arbeitspause folgende Regeln beachten:

1. Spritzpistole und Hochdruckschlauch druckentlasten.

2. Titan-Spritzpistole sichern mit Sicherungshebel am Abzugsbüge.

3. Gerät ausschalten.

Achte auf Sicherheit!

28 PowrTwin Plus

+ 82 hidden pages

Titan PoPT8900, PoPT4900, PoPT6900, PoPT12000 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual