Servicing the fluid section. Titan PowrTwin 4900 | 6900 | 8900 | 12000 Plus, PowrTwin 4900, 6900, 8900, 12000 Plus Service Manual

Maintenance

2.4 Servicing the Fluid Section

PT4900 Plus

1

2

6

3

4

5

4

10

11

12

13

7

8

9

15

3

21

16

17

18

19

20

23

14

GB

PT6900 Plus / PT8900 Plus / PT12000 Plus

1

2

6

3

4

5

8

4

9

10

11

12

13

15

3

16

17

18

19

20

21

22

14

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.

i 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.

10

Disassembling the Fluid Section

1a. Remove the siphon hose assembly. Unthread the foot valve housing (20,21) and the pump cylinder (14) with a strap wrench. i If the pump cylinder (14) cannot be removed with a strap wrench, use the removal nut (23, 22) to remove it from the pump housing.

1b. Loosen the removal nut (23, 22) on the cylinder until it bottoms out on the cylinder threads. Place a wrench on the flats of the removal nut and turn the wrench counterclockwise to loosen the cylinder.

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 flats 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, PT4900 only).

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

PowrTwin Plus

GB

Maintenance

(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)

Reassembling the Fluid Section

16. Orient the cylinder (14) with the knurled portion and removal nut at the top, thread into the block and tighten with a strap wrench.

Attention

The removal nut (23) must be kept bottomed out on the threads after the cylinder is tight. Do not use the nut to jam against the block or damage will occur during use. This nut is to be used to help with removing the cylinder only. i

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, flip the seat to the unused side. If both sides are worn, install a new seat. Place the new or flipped 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.

i 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 difficulty during reassembly.

17. Place the o-ring (15) onto the top groove 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 off to align the siphon hose.

i 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

Oil cup area for piston lube packing lubricant.

7. Inspect the outlet valve seat (11) for wear. If one side is worn, flip 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 flipped 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, PT4900 only).

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.

i

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.

Peaks of upper packings must face up.

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 11