EXPRESS MAX AIR

Full Frame Heavy Duty Air/Hydraulic Pump

Serial N°:

Date:

Gauge: N°

Titan Technologies International, Inc.

3340-B Greens Road • Suite 605 • Houston, TX.77032-2229 • USA
Tel: 281-449-9994 • Fax: 281-449-9996
WWW.TitanTi.com • [email protected]
 TECHNICAL DATA
EXPRESS AIR Model EXA-MAX

MOTOR: 3.57 Hp (2.8 Kw) at 100 psi (7 bar)

Power: Air 7bar-100psi

PUMP:
Type 3 stages
Flow 460 cu in (7.5 L/min)/min from 0 to 1000 psi ( 70 bar)
128 cu in (2.1 L/min) from 1000 psi to 2900 psi (70 to 200 bar)
55 cu in (0.9 l/min) from 2900 psi to 10,000 psi (200 to 700 bar)
Max. Pressure 10,000 psi (700 bar)

SIZE:
Length 15.75” (400 mm)
Width 14.96” (380 mm)
Height 18.31” (465 mm)

WEIGHT:
Without Oil 46 lbs (21.0 Kg)
With Oil 66 Lbs (30.0 kg)

OIL TANK: 2.38 US Gallons (9 Litres)

OIL: Use only Grade 6 mineral hydraulic oil. Proper hydraulic oil
is available from Titan Technologies.
ISO 6743-4 HV NFE 48602 HV

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WARNING!!!
Before operating the pump, make sure all hose connections are tight – use the proper
tools to tighten connections.

Do not over-tighten the connections. Connections need only to be tightened securely

and leak-free. Over-tightening may cause premature thread failure or high pressure
fittings to split at pressures lower than their rated capacities.

Hydraulic line disconnection: fully retract the cylinder and remove any load by releasing
the white button on the remote control.

Should a hydraulic hose ever burst or rupture, immediately shut off the pump. Never
attempt to grasp a leaking hose under pressure with your hands. The force of the
escaping hydraulic fluid could cause serious and permanent injury.

Avoid any condition conditions which could damage the hose and impair the pump or
valve’s performance. Never allow the hose to kink, twist, curl or bend so tightly that the oil
flow within the hose is blocked or reduce. This could damage the hose and possibly
result in serious injury to persons working in the immediate vicinity.

Do not subject the hose to any potential hazard (ex: fire, extreme heat or cold, heavy
impact or sharp surfaces) which might rupture or weaken the hose.

Periodically inspect the hose for signs of wear. Never use a defective hose with any
pressurized equipment.

Never paint the hose or the couplers!

Hose material and coupler seals must be compatible with the hydraulic fluid used.

The pump maximum working pressure is 10,000 PSI / 700 bar. Your Titan technologies
hydraulic wrenches are also rated at 10,000 PSI as are hydraulic wrenches supplied by
Titan.
If using alien equipment, please make sure that all hydraulic equipment such as
wrenches, hoses, etc. used with this pump are rated at 10,000 PSI operating
pressure.

Check for proper electrical supply before connecting.

This motor may spark. Do not operate in an explosive atmosphere or in the presence of
conductive liquids.

Compare motor nameplate against power availability to prevent motor burnout or

dangerous electrical overloading.

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 PREVENTIVE MAINTENANCE –EXPRESS AIR Pumps
WARNING: THE ELECTRICAL POWER CORD MUST BE DISCONNECTED FROM
ELECTRICAL OUTLETS BEFORE PERFORMING MAINTENANCE OR REPAIR
PROCEDURES.

EXPRESS AIR pumps are precision-built hydraulic units and, as such, do require a
certain amount of care and maintenance.

1. Hydraulic Oil: oil should be completely changed after every 40 hours of

operation, or at least twice a year. Always make sure the reservoir is filled with
fluid. If additional oil is required, use only high-grade hydraulic, such as Titan
grade 32.

2. Quick-Disconnects: Fittings should be checked periodically for leaks. Dirt

and foreign materials should be kept away from fittings. Clean before use.

3. Gauge: TITAN gauges are liquid filled. Should this liquid level drop, it
indicates external leakage, and replacement is necessary. Should the gauge
fill with hydraulic oil, it indicates internal failure and should be discarded.

4. Motor: The motor shaft and bearings should be flushed and lubricated once a
year.

5. Filter: The filter should be replaced twice a year for a normal use, and more
often if pump is in daily use.

6. Remote control: The electric cord or air line to the remote control should be
checked for kinks or obstructions periodically. If there is a bend or break in the
line, it must be replaced. The spring-loaded buttons on the remote handle
should be cheeked in the event of operating difficulties.

7. Oil tank: Should be checked in prevention of leakage.

8. Pumping unit: The pump should be overhauled every 2 years. This can be
done by TITAN or by a qualified hydraulic service center.

For longer life, it is best to keep the pump clean.

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 OPERATION MANUAL
1. Prior to using the pump:
1.1 Check oil level in reservoir.
1.2 Check the pump, remote control and hydraulic hose for signs of damage.
1.3 Connect the remote control unit.
1.4 Connect the twin line hoses and check all system fittings and connections to be sure they
are tight and leak free.
1.5 Ensure that the torque valve is set to zero by fully rotating it anti-clockwise.
1.6 Be sure the electrical connection is grounded. Check that your power agrees with the
motor nameplate. Plug power cord into outlet.

2. Operation:
2.1 Press and release the white button on the remote control to START THE PUMP.
2.2 The tool is pressurised by holding the white button down and pressurised by releasing it.
2.3 Press the black button to STOP THE PUMP.
2.4 The motor will automatically switch off approximately 1 minute after the last operation on
the remote control.
2.5 Bleed to the pump to ensure that there air is purged from the system, by opening the
torque control valve fully anti-clockwise and with motor running hold the white button
down for 15-20 seconds release and repeat.

3. Torque Setting:
Make these adjustments BEFORE putting torque wrench on nut or bolt head.
3.1 See torque wrench chart to have the amount of pressure required to produce desired
torque.
3.2 Test cycle hydraulic wrench on the floor or work bench (off-load) to ensure proper mating
of quick connects and system as a whole.
3.3 Press and hold the white button to advance the piston.

3.4 While holding the button, slowly turn the pressure valve (clockwise) to increase pressure
on the gauge.
3.5 Stop when the required pressure appears on the gauge and release the button.
3.6 Repeat the 3.2 to control that the pressure on the gauge is right.
3.7 If the pressure on the gauge is not good, repeat step 3.2 to 3.5.
3.8 Once the desired pressure has been reached tighten the lock nut on the pressure valve.
3.9 You can put the tool on the nut and run the pump.

4. After use:
Be sure that there is no pressure in the line:
4.1 Switch off the pump using the black button on the remote control.
4.2 Turn off the electrical supply.
4.3 Disconnect the hydraulic hoses.

It’s very important to keep the pump unit clean after use and before storage.

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HYDRAULIC SCHEMATIC

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PUMP SCHEMATIC

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 Spare parts list

1 Motor

2 Internal spare

2.1 Seals and bearing

3 Oil tank

4 Hex pipe plug

5 Thermometer/Oil level.

6 Filler plug

7 Back pressure valve-Manifold ass.

8 Hydraulic couplers.

9 Pressure regulator valve.

10 Gauge

11 Solenoid valve

12 Frame.

13 Filter - Regulator- Lubricator.

14 Remote control

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 TROUBLE SHOOTING GUIDE
Problem Probable cause Solution

Motor runs but no reaction 1. Quick connect not mated 1. Tighten connection until fully
with the tool properly. secure.
2. Damaged Connect 2. Replace.
3. No or too little oil in reservoir 3. Control and fill up oil level.
4. Pressure regulator valve too 4. Increase.
slow
5. Defective remote control hose 5. Replace.

Tool will not retract 1. Same as above 1. Same as above

Tool cannot be removed 1. Holding Reaction Pawl is 1. Pressurize the tool and while
engaged. keeping the button depressed on
the remote control, GENTLY pull
back the pawl release lever on the
side of the tool. Release the button
on the remote & let the piston
retract.
2. Cylinder did not retract 2. Check quick connect as
described above.

Tool leaks oil 1. Seal damage in cylinder 1. Replace seal.

2. Seal damage in Tru-Swivel 2. Replace seal.

Tool advance in "retract" 1. Quick connects installed in 1. Make sure connects are set up
Mode or "Visa Versa" improper sequence. in the right way.

Ratchet returns on retract 1. Missing, defective or broken 1. Change pawl spring or Reaction
Stroke. Reaction Pawl Pawl.

Tool will not take successive 1. Lose or defective quick 1. Fully tighten or replace connects
Strokes connect. on retract side.
2. Operator is depressing advance 2. Wait for oil to return and for the
before oil has a chance to fully cylinder to retract completely
return to the reservoir, thus before taking the next stroke.
preventing the piston from fully
returning before taking the new
stroke.
3. Defective Drive Pawl spring 3. Replace the spring.
4. Broken Drive Pawl 4. Replace.

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Motor doesn't run 1. No source 1. Connect air line.
2. Pump starved for air 2. Use minimum1"dia. Air hose,
Need 50 cfm.100psi 6bar air
source.
3. Inadequate power supply 3. Use proper power source.
4. Defective remote control hose 4. Replace remote control.

Air pump Sluggish 1. Pump starved for air 1. Use minimum1"dia. Air hose,
Need 50 cfm.100psi 6bar air
source.
2. Dirt in air motor 2. Flush motor with solvent, clean,
dry and lubricate.
3. Dirty Oil Filter 3. Clean or replace.

Air motor frozen 1. FLR missing or broken 1. Replace FLR.

2. Rotor bearings frozen 2. Inspect & replace.
3. Obstruction in air valve 3. Inspect & clean.
4. Improperlly installed remote 4. Ensure 3-hose system is
control hoses connected properly.(color coded)
5. Defective remote control hoses 5. Replace.
6. Defective remote button 6. Replace spring.

Pump will not build pressure 1. Inadequate power supply 1. Use proper power source.
2. Pump starved for air 2. Use minimum1"dia. Air hose,
Need 50 cfm.100psi 6bar air
source.
3. Defective pressure regulator 3. Replace.
valve
4. Defective gauge 4. Replace.
5. Dirty oil 5. Clean reservoir and replace oil.
6. Clogged FRL 6. Replace FLR.

Drop oilier doesn't work 1. No or too little oil in reservoir 1. Control and fill up oil level.
2. Drop oilier misplaced 2.Adjust to 5-6 drops/min

No pressure reading on 1. Defective gauge 1.Replace gauge.

gauge
2. Loose connect 2. Tighten connect.
3. Defective seals 3. Inspect all seals and replace
any defective one.
4. Defective motor coupling. 4. Replace motor coupling.

3340-B Greens Rd * Suite 605 * Houston, TX 77032

Tel: 281-449-9994 Fax: 281-449-9996

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