Models LP301A & LP600
Contents
1. Repair or replacement of defective products as provided is the sole and exclusive remedy provided hereunder and the MANUFACTURER SHALL NOT BE LIABLE FOR FURTHER LOSS DAMAGES OR EXPENSES INCLUDING INCIDENTAL AND CONSEQUENTIAL DAMAGES DIRECTLY OR INDIRECTLY ARISING FROM THE SALE OR USE OF THIS PRODUCT THE LIMITED WARRANTY SET FORTH HEREIN IS IN LIEU OF ALL OTHER WARRANTIES OR REPRESENTATION EXPRESS OR IMPLIED INCLUDING WITHOUT LIMITATION ANY WARRAN TIES OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE AND ALL SUCH AS PLAN IVF ATN 5 5 Y DISCLAIVIED AIND CLUDED D VIAINOUrAC TORER GIANT INDUSTRIES INC 900 N Westwood Ave P O Box 3187 Toledo Ohio 43607 PHONE 419 531 4600 FAX 419 531 6836 www giantoumps com Copyright 2002 Giant Industries Inc 4 02 LP301600 PM62. 29B If plunger pipe is worn out 13 Replace complete seal sleeve loosen tension screws 29C with a 15mm socket and pull off 35 seal case 37 assembly plunger pipe to the front Clean front surface of plunger 29B into crankcase 1 Make thoroughly Apply a small drop of locktite to tension screw Put sure that the weep hole a new crush washer 29D onto tension screw Put a thin coat points downward Note To of glue Loctite on the ring or ceramic plunger side and replace the oil seals 31 tighten screw to 265 in Ibs you will need to disas semble the gear end see instructions below 14 Place entire manifold seal case sleeve assembly over the 15 Tighten hex nuts 49A in a studs and push firmly until crosswise pattern shown seated against the crank above to 59 ft Ibs LP301A LP600 REPAIR INSTRUCTIONS TO DISMANTLE GEAR END After removing valve casing 43 and plunger pipe 29B drain the oil Remove the gear cover 4 and both bearing covers 14 Loosen connecting rod screws 24A and push the front of the connecting rod 24 forward as far as possible into the crosshead guide IMPORTANT Connecting rods 24 are marked for identification Do not twist connecting rod halves Connecting rod is to be reinstalled in the same position on shaft journals Turning the crankshaft 22 slightly hit it out carefully to the side with a rubber hammer IMPORTANT Do not bend the connecting rod 24 shanks Check crankshaf
3. But if it is used carelessly and without regard to its potential hazard it can cause serious injury IMPORTANT OPERATING CONDITIONS Failure to comply with any of these conditions invalidates the warranty 1 Prior to initial operation add oil to the crank case so that oil level is between the two lines on the oil dipstick DO NOT OVERFILL Use SAE 85 140 industrial gear oil Crankcase oil should be changed after the first 50 hours of operation then at regular intervals of 500 hours or less depending on operating conditions 2 Pump operation must not exceed rated pressure volume or RPM A pressure relief device must be installed in the discharge of the system 3 Acids alkalines or abrasive fluids cannot be pumped unless approval in writing is obtained before operation from Giant Industries Inc 4 Run the pump dry approximately 10 seconds to drain the water before exposure to freezing temperatures NOTE Contact Giant Industries for Service School Information Phone 419 531 4600 Specifications Model LP301A Ratings CONEIIMOUS sersmersrirae 14 1 GPM 4000 PSI 1000 RPM Ratings internmittent aeaysecsectacenesswecgsovacedinsverwiesennreaatteaaesreteneaciiees 18 GPM 4000 PSI 1277 RPM let FCS i oenar E E R EEE SE Up to 140 Pl nger Diameter sorsien E E 24 mm OR patel E A E A AEE AE 42 mm Crankcase Oil Capacity cicscicacsnxncdasantcdeesantcscundedcehinosee dono easenipeacestetdasaetdacsss 100 fl oz Te
4. Oty 3 3 3 3 3 LP600 09195 Item Part Description 46A 07064 Valve Seat 46B 13130 Valve Plate 46C 07062 Valve Spring 44A 07150 O Ring 44B 06266 Support Ring Qty 3 3 3 6 3 I I H H H 00 DDWADAAAAAWHOHUWUUWAAWU LHW a a a uf KK LP600 09197 Item Part Description 36 13237 Leakage Seal 38 07140 O Ring 38A 13241 Support Ring 39 07141 O Ring 39A 13036 Support Ring 40 07322 V Sleeve 6 40A 07268 Pressure Ring eee ee Go Specifications Model LP600 PON IN Sonesta se tocntele aac E S N EE esos Up to 9 7 GPM Discharge 2 co lt a nen ne ee tes Up to 6000 PSI mle Pre Lg cae een eee E ne ee Re oe Re ee ere Up to 90 PSI OPEC ase ge rea ethene tee E sa aetna ase Seas ero eee researc Up to 1000 RPM POTN Ge Dian Ier ater aero tse tts A E EA EE A N 20 mm OO ea E erases uncer eons EA AEEA EA 42 mm Crank Case Oil Capacity ojoccisassacnsusaiertunsssoscosssencoiesncantesndntanenteimadodsansiotaetens 100 fl oz Temperature of Pumped IIS otc aeacsireteccerteaarasstaeotarsieeasions Up to 140 F TEINS POR E sesso ce ect E E E E E E tee E desetene 1 1 4 BSP Discharge 0 9 Le nee me on i ASEE is 1 BSP Crankshaft Mounting sicuecynneagecanc scone aieeunoueaieeeuieee ies nee nes Either Side SDAL ROLIO ne ne E E ESET Top of Pulley Towards Fluid End IM E E T 110 lbs Crankshaft Diameter 000 00ccccccecccccccceceeceeeseeeeeseeeetseeesseeeesseeeenseeeesas 35 mm Intermittent duty for pump speedsin excess of 805
5. RPM PULLEY INFORMATION Pulley selection and pump speed are based on a1725RPMmotor and B section belts When selecting desired GPM allow for a 5 toler ance on pumps output due to variations in pulleys belts and motors among manufactur ers HORSEPOWER INFORMATION We recommend that a 1 1 service factor be specified when selecting an electric motor as the power source To compute specific pump horsepower requirements use the following formula HP GPM X PSI 1440 1 Select GPMrequired then select appropriate motor and pump pulley from the same line 2 The desired pressure is achieved by selecting the correct nozzle size that corresponds with the pump GPM LP600 PULLEY SELECTION AND HORSEPOWER REQUIREMENTS PUMP MOTOR GPM PULLEY PULLEY RPM 3000 PSI 4000 PSI 5000 PSI 6000 PSI 735 6 2 7 28 z 3 4 9 1 9 7 ON LP301A LP600 REPAIR INSTRUCTIONS NOTE Always take time to lubricate all metal and non metal parts with a light film of oil before reassembling This step will help ensure proper fit at the same time protecting the pump non metal parts elastomers from cutting and scoring TO CHECK VALVES 1 Loosen and remove tension 2 Remove the support ring 3 Take out discharge valve as plugs 48 with a 36mm 44B o ring 44A and ten semblies 46 by pulling them socket wrench sion spring 45 upwards out of the valve casing 43 with a snap ring tongs or any other pull off device Then remo
6. Triplex Ceramic Plunger Pump Operating Instructions Manual Models LP301A amp LP600 Contents Installation Instructions page 2 LP301A Specifications page 3 Exploded View page 4 Parts List Kits page 5 LP600 Specifications page 6 Repair Instructions page 7 10 Pump Mounting Selection Guide page 10 Torque Specifications page 10 Trouble Shooting Preventative Maintenance Check List amp Recommended Spare Parts List page 11 Dimensions back page Warranty Information back page Updated 4 02 INSTALLATION INSTRUCTIONS Installation of the Giant Industries Inc pump is not a complicated procedure but there are some basic steps common to all pumps The following information is to be considered as a general outline for installa tion If you have unique requirements please contact Giant Industries Inc or your local distributor for assistance 1 The pump should be installed flat on a base to a maximum of a 15 degree angle of inclination to ensure optimum lubrication 2 The inlet to the pump should be sized for the flow rate of the pump with no unnecessary restrictions that can cause cavitation Teflon tape should be used to seal all joints If pumps are to be operated at temperatures in excess of 140 F it is important to insure a positive head to the pump to prevent cavitation 3 The discharge plumbing from the pump should be properly sized to the flow rate to prevent line pressure
7. ace packing Check system for stoppage air leaks correctly sized inlet plumbing to pump Recharge Replace accumulator Check for proper operation Check inlet lines for restrictions and or proper size Re size discharge plumbing to Drop at flow rate of pump Rated Replace plungers Adjust or Replace packing seals Reduce suction vacuum Replace plungers Reduce inlet pressure Giant oil is recommended Adjust oil level to proper amount Preventative Maintenance Check List amp Recommended Spare Parts List Check Oil Level Quality Oil Leaks Water Leaks Belts Pulley Plumbing Daily Weekly SO0hrs Oil Change 1 Gallon p n 1154 Seal Spare Parts 1 kit pump Valve Spare Parts 1 kit pump Every 500 hrs Every 1500 hrs Every 3000 hrs LP301A LP600 DIMENSIONS mm Fitting Key 385 S12 123 344 x i IANN ba ol J Ly n 3 aN 18 i Ta 4 x M12 415 wn 210 INLET Connection 2x 1 1 4 BSP GIANT INDUSTRIES LIMITED WARRANTY Giant Industries Inc pumps and accessories are warranted by the manufacturer to be free from defects in workmanship and material as follows 1 will pump warranted SALINE 2 3 4 For portable pressure washers and car wash applications the discharge manifolds never fail period If they ever fail we will replace them free of charge Our other parts used in portable pressure washers and in car wash applications are for five years from the date o
8. al LP301A Seal Case LP600 Seal Case LP301A O Ring Seal Case Support Ring for 38 O Ring LP600 O Ring LP301A Support Ring for 39 LP600 Support Ring for 39 LP301A V Sleeve LP600 V Sleeve LP301A Pressure Ring LP600 Pressure Ring LP301A Support Ring for 40 LP600 Guide Ring for 40 LP301A Pressure Spring LP301A only Valve Casing O Ring Support Ring for O Ring Compression Spring Valve Assy Complete LP600 Valve Assy Complete LP301A Valve Seat Valve Plate LP600 Valve Plate LP301A Valve Spring Spacer Pipe Plug Stud bolt Hexagon Nut Disc Plug G 1 2 S S LP301A only Steel Ring LP301A only Disc for Crankshaft Hexagon Screw Plug G 1 Plug G 1 1 4 LP301A LP600 REPAIR KITS Plunger Packing Kits LP301A 09459 For pumps manufactured on or after 4 96 Item Part Description Qty 36 13238 Leakage Seal 3 38 07140 O Ring 3 38A 13241 Support Ring 3 39 12055 O Ring 3 39A 07693 Support Ring 3 40 06083 V Sleeve 6 40A 13366 Pressure Ring 3 Valve Kits LP301A 09196 Item Part Description Qty 46A 07064 Valve Seat 3 46B 07063 Valve Plate 3 46C 07062 Valve Spring 3 44A 07150 O Ring 6 44B 06266 Support Ring 3 LP301A For pumps manufactured before 4 96 Description Leakage Seal Item 36 38 39 40 Part 13238 07140 13241 12055 07693 13049 13366 09198 O Ring Support Ring O Ring Support Ring V Sleeve 6 Support Ring
9. f shipment for all pumps used in NON clean water applications One 1 year from the date of shipment for all other Giant industrial and consumer pumps Six 6 months from the date of shipment for all rebuilt pumps Ninety 90 days from the date of shipment for all Giant accessories This warranty is limited to repair or replacement of pumps and accessories of which the manufacturer s evaluation shows were defective at the time of shipment by the manufacturer The following items are NOT covered or will void the warranty Defects caused by negligence or fault of the buyer or third party Normal wear and tear to standard wear parts Use of repair parts other than those manufactured or authorized by Giant Improper use of the product as a component part Changes or modifications made by the customer or third party The operation of pumps and or accessories exceeding the specifications set forth in the Operations Manuals provided by Giant Industries Inc oo a Liability under this warranty is on all non wear parts and limited to the replacement or repair of those products returned freight prepaid to Giant Industries which are deemed to be defective due to workmanship or failure of material A Returned Goods Authorization R G A number and completed warranty evaluation form is required prior to the return to Giant Industries of all products under warranty consideration Call 419 531 4600 or fax 419 531 6836 to obtain an R G A number
10. l Sight Glass w Gasket 7 07187 Gasket For Sight Glass 8 06086 Oil Dipstick Assy 9 01009 O Ring For Dipstick 10 01010 Cylinder Screw 11 08094 Spring Ring 12 07109 Plug G1 2 13 07182 Gasket 14 07111 Bearing Cover 15 07112 Radial Shaft Seal 16 07113 O Ring for Bearing Cover 17 07114 Hexagon Screw 20 07116 Taper Roller Bearing 20A 07117 Fitting Disc 20B 13001 Fitting Disc 21 07118 Shaft Protector 22 13242 Crankshaft 23 13243 Woodruff Key 24 13340 Connecting Rod Assy 24A 13277 Inner Hex Screw 24B 13278 Spring Washer 25 13341 Crosshead Assy 28 13232 Crosshead Pin 29A 07125 Centering Sleeve 29B 07126 Plunger Pipe LP600 29B 07127 Plunger Pipe LP301A 29C 07131 Tensioning Screw 29D 07755 Copper Ring 29D 07161 0100 Oil Seal 30 07779 Oil Scraper 31 07133 Oil Seal 35 13235 Seal Sleeve LP600 35 13364 Seal Sleeve LP301A 36 13237 Leakage Seal LP600 WONNNRF RUD BPR KR Re eee pmi I W U WWWWWWWWWWWWWOADWHHE This seal replaces former oil seal assembly p n 06120 ITEM 36 37 37 38 38A 39 39 39A 39A 40 40 40A 40A 40B 40B Al 43 44A 44B 45 46 46 46A 46B 46B 46C 46D 48 49 49A 49B 50 50A 52 53 54 39 PART 13238 13239 13240 07140 13241 07141 12055 13036 07693 07322 06083 07268 13366 07270 13438 07338 13040 07150 06266 06078 07067 07060 07064 13130 07063 07062 07066 06077 07157 07158 07159 12250 13439 13020 06607 13044 13151 DESCRIPTION Leakage Se
11. loss to the work area It is essential to provide a safety bypass valve between the pump and the work area to protect the pump from pressure spikes in the event of a blockage or the use of a shut off gun 4 Use of a dampener is necessary to minimize pulsation at drive elements plumbing connec tions and other system areas The use of a dampener with Giant Industries Inc pumps is optional although recommended by Giant Industries Inc to further reduce system pulsa tion Dampeners can also reduce the severity of pressure spikes that occur in systems using a shut off gun A dampener must be positioned downstream from the unloader 5 Crankshaft rotation on Giant Industries Inc pumps should be made in the direction desig nated by the arrows on the pump crankcase Reverse rotation may be safely achieved by following a few guidelines available upon request from Giant Industries Inc Required horsepower for system operation can be obtained from the charts on pages 3 and 6 6 Before beginning operation of your pumping system remember Check that the crankcase and seal areas have been properly lubricated per recommended schedules Do not run the pump dry for extended periods of time Cavitation will result in severe damage Always remember to check that all plumbing valves are open and that pumped media can flow freely to the inlet of the pump Finally remember that high pressure operation in a pump system has many advantages
12. mperature of 50000 0 cz 008 cll D1 6 cea ene en ee nO Up to 140 F let PONT an a E E E EAEE E A E 1 1 4 BSP Dicha se PO e e E E 1 BSP Crank Dani Mounin ee ee eee ee a ETE i Either Side onat ROTAN Olsan ne TAa anh era eR ran aiea aE aE Top of Pulley Towards Fluid End ME rae ee a A E E T E A 110 lbs Crankshait DIdinciGi sesegera nn E EEEE E AE 35 mm PULLEY INFORMATION HORSEPOWER INFORMATION Pulley selection and pump speed are based on We recommend that a 1 1 service factor be a 1725 RPM motor and B section belts When specified when selecting an electric motor as selecting desired GPM allow for a 5 toler the power source To compute specific pump ance on pumps output due to variations in horsepower requirements use the following pulleys belts and motors among manufactur formula ers HP GPM X PSI 1440 1 Select GPMrequired then select appropriate motor and pump pulley from the same line 2 The desired pressure is achieved by selecting the correct nozzle size that corresponds with the pump GPM LP301A PULLEY SELECTION AND HORSEPOWER REQUIREMENTS PUMP MOTOR PULLEY PULLEY RPM GPM 2500 PSI 3000 PSI 3500 PSI 4000 PSI 12 75 12 75 12 75 12 75 12 75 12 75 12 75 12 75 Intermittent duty only Exploded View LP301A LP600 LP301A LP600 PARTS LIST QTY ITEM PART DESCRIPTION 1 07759 Crankcase Z 13000 Oil Filler Plug Assy 4 06085 Crankcase Cover 5 07104 O ring Crankcase Cover 6 07186 Oi
13. t 22 and connecting rod 24 surfaces radial shaft seals 15 and taper roller bearings 20 To remove the oil seals 31 use a wooden rod and sharply hit down on the oil seals from the crankcase 1 Note when replacing the oil seals apply a small amount of locktight to the outside edges of each oil seal before re inserting them into the crankcase To Reassemble Using a soft tool press in the outer bearing ring until the outer edge lines up with the outer edge of the bearing hole Remove bearing cover 14 together with radial shaft seal 15 and o ring 16 Fit crankshaft 22 through bearing hole on the opposite side Press in outer bearing and tighten it inwards with the bearing cover keeping the crankshaft in vertical position and turning slowly so that the taper rollers of the bearings touch the edge of the outer bearing ring Adjust axial bearing clearance to at least 0 1mm and maximum 0 15mm by placing fitting discs 20A and 20B under the bearing cover IMPORTANT After assembly has been completed the crankshaft should turn easily with very little clearance Tighten connecting rod screws 24A to 310 in lbs Re assemble the fluid end see instructions above LP301A LP600 TORQUE SPECIFICATIONS Position lItem Description Torque Amount 24A 13277 Inner Hex Screw Connecting Rod 310 in lbs 29C 07131 Tension Screw Plunger 265 in lbs 48 06077 Plug Discharge 107 ft lbs 49A 07158 Hexagon Nut Stud Bolts 59 ft lbs Pump Mo
14. unting Selection Guide Bushings 06496 35 mm H Bushing Pulley amp Sheaves 07165 12 75 Cast Iron 4 gr AB Section Rails 07357 Plated Steel Channel Rails L 11 75 x W 1 88 x H 3 00 10 MALFUNCTION The Pressure and or the Delivery Drops Water in crankcase Noisy Operation Rough Pulsating Operation with Pressure Drop Pump Pressure as gun Pressure Excessive Leakage High Crankcase Temperature PUMPSYSTEM MALFUNCTION CAUSE Worn packing seals Broken valve spring Belt slippage Worn or Damaged nozzle Fouled discharge valve Fouled inlet strainer Worn or Damaged hose Worn or Plugged relief valve on pump Cavitation pump for restrictions Unloader High humidity Worn seals Worn bearings Cavitation Worn packing Inlet restriction Accumulator pressure Unloader Cavitation Restricted discharge plumbing Worn plungers Worn packing seals Excessive vacuum Cracked plungers Inlet pressure too high Wrong Grade of oil Improper amount of oil in crankcase REMEDY Replace packing seals Replace spring Tighten or Replace belt Replace nozzle Clean valve assembly Clean strainer Repair Replace hose Clean Reset and Replace worn parts Check suction lines on inlet of Check for proper operation Reduce oil change interval Replace seals Replace bearings Refill crankcase oil withrecommended lubricant Check inlet lines for restrictions and or proper sizing Repl
15. ve inlet valves in the same way 4 Loosen valve seats 46A and valve spring 46C from 5 Tighten up tension plugs 48 spacer pipe 46D by lightly to 107 ft lbs hitting the valve plate 46B with a plastic stick Check sealing surface and replace worn parts Reassemble with new o rings 44A if possible and oil them before installing LP301A LP600 REPAIR INSTRUCTIONS NOTE Always take time to lubricate all metal and non metal parts with a light film of oil before reassembling This step will help ensure proper fit at the same time protecting the pump non metal parts elastomers from cutting and scoring TO CHECK SEALSAND PLUNGER PIPE 6 Loosen the 8 nuts 49A 7 Remove the seal sleeve 35 8 Remove seal case 37 from with a 19mm socket and from the manifold and or seal sleeve 35 pull off valve casing 43 crankcase to the front 9 Check O rings 39 amp 38 and support rings 39A amp 38A on seal case 37 10 Remove leakage seal 36 11 Remove the pressure ring 40A v sleeves 40 and support from the seal sleeve If worn ring 40B from the seal sleeve For LP301A pumps remove or damaged replace with the pressure spring 41 Examine seals carefully and replace if new seal worn Clean surfaces of seal sleeves 35 which come in contact with the crankcase 1 and sealing surfaces of valve casing 43 LP301A LP600 REPAIR INSTRUCTIONS U f Hole g 12 Check plunger surface
Download Pdf Manuals
Related Search