HP LP350 User's Manual
Contents
1. 38 7140 38A 13012 40 13016 41 7150 Description Qty O ring 3 O ring 3 V sleeve 6 O ring 3 Packing Kit LP400 09309 prior to 2 97 ltem Part 38 07140 38A 13012 40 13049 40A 13050 Description Qty O ring 3 O ring 3 V sleeve 3 Support ring 3 Packing Kit LP450 prior to 2 97 09234 Item Part 38 07140 38A 12055 4 13015 41 06652 Description Qty O ring 3 O ring 3 V Sleeve 6 O ring 3 Packing Kit LP350 409546 after 2 97 Item Part Description Qty 38 07700 O Ring 6 40 13016 V Sleeve 6 Packing Kit LP400 09548 after to 2 97 Item Part 38 07140 38A 12055 40 06083 Description Qty O ring 3 O ring 3 V sleeve 6 Packing Kit LP450 09549 after to 2 97 Item Part Description Qty 38 07700 O ring 6 40 13015 V Sleeve 6 PART 06650 13393 06651 07140 07700 12055 07271 13016 13013 13016 06083 13015 07273 13367 06652 07338 14084 13018 07150 06266 06078 07060 07064 07063 07062 07066 07156 07754 07158 07159 07423 07161 13020 06607 24 29C 49A DESCRIPTION Seal Sleeve LP350 LP450 Seal Case LP400 SealCase LP350 LP450 O Ring LP400 O Ring LP350 LP450 O Ring LP400 Only Pressure Ring LP350 Pressure Ring LP400 Pressure Ring LP450 V Sleeve LP350 V Sleeve LP400 V Sleeve LP450 Support Ring LP350 Support Ring LP400 Support Ring LP450 Pressure Spring LP400 Pressure Spring LP350 LP450 Valve Casing O Ring Support Ring Compression2. 395 500 9 8 68 10 3 137 17 8 22 7 28 6 26 7 30 7 33 4 LP350 LP400 LP450 EXPLODED VIEW AJUC 0Yd 1 vas LP350 LP400 Y LP450 PARTS LIST ITEM PART DESCRIPTION OTY ITEM 1 07759 Crankcase 1 35 2 13000 Oil filler plug assy 1 37 4 06085 Crankcase Cover 1 37 5 07104 O ring Crankcase cover 1 38 6 07186 Oil Sightglass with Gasket 1 38 8 06036 Oil Dipstick 1 38A 9 01009 O Ring Dipstick 1 39 10 01010 Cylinder Screw 4 39 11 01011 Spring Ring 5 39 12 07109 Plug 1 40 13 07182 Gasket 1 40 14 07111 Bearing Cover 2 40 15 07112 Radial Shaft Seal 2 41 16 07113 O Ring 2 41 17 07114 Hexagon Screw 8 41 20 07116 Taper Roller Bearing 2 42 20A 07117 Fitting Disc 1 3 42 20B 13001 Fitting Disc May not be present 1 3 43 21 07118 Shaft Protector 1 44A 22 13242 Crankshaft 1 44B 23 13243 Woodruff Key 1 45 24 13340 Connecting Rod Assy 3 46 24A 13277 Inner Hexagon Screw 6 46A 24B 13278 Spring Washer 6 46B 23 13244 Crosshead Plunger Assy 3 46C 28 13232 Crosshead Pin 3 46D 29A 07256 Centering sleeve 3 48 29B 13046 Plunger Pipe LP400 3 49 29B 13005 Plunger Pipe LP450 3 49A 29B 07261 Plunger Pipe LP350 3 49B 29C 13007 Tensioning Screw 3 50 29D 07258 Copper Ring 3 SOA 30 07779 O Ring 3 52 31 07133 Oil Seal 3 53 35 13392 Seal Sleeve LP 400 3 LP350 LP400 amp LP450 KITS Pumps Manufactured Prior to 2 97 Pumps Manufactured After 2 97 Packing Kit LP350 09233 prior to 2 97 Item Part
3. Plunger Diameter ocooonccnnocnncnncnnnnnnnnnnncnnnonnnnnnnncnnnnnnnnonnnononnnnonnnnnnnnannnns 28mm ROLL OS 42mm LIKE VIE D0 alo olaa cios 100 fl oz Temperature of Pumped Fluids o cccooccnccncnnnnncnnnoncnnnoncnnnnnnnnnnnannnonanoss 140 F 1000 RPM a sods ss eae eeu ee 160 F Up to 500 RPM A E a i 1 1 4 BSP DISCM ar CCP OL xedos as ayia aS staan hana 1 BSP Shaft Mounting Either side o AAA Top of pulley towards manifold co Fa ee eee NENEN E ENNEN ENNEN eter Meme mee renee D 105 Ibs AN FEN 01 Cs aps ene a nj 35mm PULLEY INFORMATION HORSEPOWER INFORMATION Pulley selection and pump speed are based on a 1725 RPM motor and B section belts When selecting desired GPM allow for a 5 tolerance on pumps output due to variations in pulleys belts and motors among manufacturers 1 Select GPM required 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 Horsepower ratings shown are the power require ments for the pump Gas engine power outputs must be approximately twice the pump power requirements shown above 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 LP450 PULLEY SELECTION AND HORSEPOWER REQUIREMENTS PUMP MOTOR 12 75
4. ROHO izsak s rt s v n s Top of pulley towards manifold bc A 60 S SSS 105 lbs CESADO e 33mm PULLEY INFORMATION HORSEPOWER INFORMATION Pulley selection and pump speed are based on a 1725 RPM motor and BP section belts When selecting desired GPM allow for a 5 tolerance on pumps output due to variations in pulleys belts and motors among manufacturers 1 Select GPM required 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 Horsepower ratings shown are the power require ments for the pump Gas engine power outputs must be approximately twice the pump power requirements shown above 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 GPM LP350 PULLEY SELECTION AND HORSEPOWER REQUIREMENTS PUMP MOTOR 12 75 655 865 195 68 136 271 312 Specifications Model LP400 A A Up to 15 1 GPM Discharge Pressure AAA A AAA 3600 PSI TECATE SUE VA YAA AAA AAA Up to 90 PSI Maximum Crankshaft Speed oocccooccccooccnnoncnnnoncnnnoncnnnonncnnnnnnnnonnnnonanoss Up to 1000 RPM eiii sos 36033000 yo nate 24mm O N NN AA 42mm Crankcase Oil CAPA tc 100 fl oz Temperature of Pumped Fluids 00 0 aaa 140 F 1000 RPM ba adu au auss ss
5. Spring Valve Assy Valve Seat Valve Plate Valve Spring Spacer Pipe Plug Stud bolt Hexagon Nut Disc Plug 1 4 BSP Copper Ring Disc for Crankshaft Hexagon Screw HHH Hmm ew AnADABWLOHBUBEBADABEHwAWwY wf Valve Kit 09196 Item Part Description Qty 44A 07150 O Ring 6 44B 06266 Support Ring 3 46A 7064 Valve seat 1 46B 7063 Valve plate 1 46C 7062 Valve spring 1 TORQUE SPECIFICATIONS Position Description Torque Amount Connecting Rod 264 in lbs Tensioning Screw 33 ft lbs Hexagon Nut 59 ft lbs MALFUNCTION The Pressure and or the Delivery Drops Water in crankcase Noisy Operation PUMP SYSTEM MALFUNCTION CAUSE Worn packing seals Broken valve spring Belt sl ppage 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 oil with 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 recommended lubricant Cavitation Check inlet lines for restrictions and or proper sizing Rough Pulsating Worn packing Replace packing Operation with Pressure Drop Pu
6. tension plugs 48 from top pulling them upwards out of rod through the top of spacer of valve casing 43 the valve casing 43 It pipe 46D Hold assembly maybe necessary to use a in hand and tap end of dowel slide hammer tool sharply with mallet until as sembly breaks free 4 Inspect valve seats 46A and valve plates 46B for damage 5 Replace tension plugs 48 and replace if needed Check valve casing 43 surfaces for and tighten them securely damage Replace o rings 44A and reinstall valve assemblies 46 into valve casing Lubricate o rings before installation SEAL AND PLUNGER REPLACEMENT 6 Remove the eight 8 7 If needed tap valve casing 8 Using two flat screw drivers manifold nuts and washers with a rubber mallet to re pry seal sleeve 35 out of 49A B using a 19mm move it crankcase guides wrench and pull off valve casing 43 REPAIR INSTRUCTION LP350 LP400 LP450 J li 7 F1 a F7 E ie zili C 9 Remove seal case 37 from 10 Check plunger surface 25 11 If plunger 29B is worn re seal sleeve 35 and 29B for wear and pit move tension screw 29C ting If none is found pro with a 17mm wrench Clean ceed to step twelve tension screw with wire brush to remove any old locktite Discard copper gas ket 29D and replace with new Clean the front surface of plunger crosshead as sembly 25 Install new plunger 29B onto plunger crosshea
7. 160 F Up to 500 RPM Inlet Port A E e a i nn 1 1 4 BSP Discharce Portu id 1 BSP Si AAA taletstatetataletstehea tel ttehal celts ta aatabes Either side Shaft ROON nic a a i a aa Top of pulley towards manifold MEDD ae E A E AA S aN eT 105 lbs Crankshatt Diametro 33mm PULLEY INFORMATION HORSEPOWER INFORMATION Pulley selection and pump speed are based on a 1725 RPM motor and BP section belts When selecting desired GPM allow for a 5 tolerance on pumps output due to variations in pulleys belts and motors among manufacturers 1 Select GPM required 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 Horsepower ratings shown are the power require ments for the pump Gas engine power outputs must be approximately twice the pump power requirements shown above 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 LP400 PULLEY SELECTION AND HORSEPOWER REQUIREMENTS PUMP MOTOR 18 8 12 75 495 640 9 6 134 167 201 241 28 2 Specifications Model LP450 MO Lodi o A A Up to 19 7 GPM DISTA Pressin oeaiei a 2600 PSI EA a a Up to 90 PSI Maximum Crankshaft Speed oooccoooccnncocnnncncnnnnncnnnonoconononononacnnoncnnnncnnnns Up to 1000 RPM
8. Models Triplex Ceramic Plunger Pump Operating Instructions Repair and Service Manual LP350 LP400 LP450 Updated 2 02 Contents Installation Instructions Pump Specifications Exploded View Parts List Kits Torque Specs Trouble Shooting Chart Spare Parts List Repair Instructions Dimensions Warranty Information page 2 pages 3 5 page 6 page page 8 page 8 page 9 11 back page back page 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 unigue reguirements please contact Giant Industries Inc or your local distributor for assistance 1 The pump should be installed flat on a base to a maximum ofa 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 loss to the work area It is essential to provide a safety bypass valve between the pump and the work area to
9. PORTANT OPERATING CONDITIONS Failure to comply with any of these conditions invalidates the warranty 1 Prior to initial operation add oil to the crankcase so that oil level is between the two lines on the oil dipstick DO NOT OVERFILL Use SAE 90 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 Specifications Model LP350 O LD A sd N Up to 22 6 GPM Dise harte Presse ona ll 2350 PSI MA ias on erento nd aia sansa Up to 90 PSI Maximum Crankshaft Speed occooocccccoccnccncnnncncnnnnnnnnnnonncnnonnnnnonncnnonanoss Up to 1000 RPM Plunger Diametro is 30mm NOLO oer ee re SSS ea dj N UNNCe Teme TRNeeTeeSnE ee eet 42mm Crankease Oil Cap aC iy shes heats aes oem ounce oem ses S S 100 fl oz Temperature of Pumped Fluids aaa 140 F 1000 RPM A OES 160 F Up to 500 RPM Inlet POTS SS 1 1 4 BSP DISCAL A tet ele tin ot ite ico a Wiis ois Ds OS es 1 BSP Shaft MOUNTING zz eee ausma ke u Sa Either side Shalt
10. d assembly Put some locktite on both sur faces of copper gasket and tension screw threads Se cure plunger in place with tension screw and gasket and tighten to 33 ft lbs 41 42 38 38A 37 38 LP400 only 12 Remove v sleeves 40 and support ring 41 for seal case 37 13 Place entire manifold assem and replace with new elastomers Lubricate parts before bly sleeve assembly over the reinstalling into seal sleeve Replace seal sleeve seal case studs 49 and push firmly assembly 35 37 into the valve casing 43 until seated againstthe crank case 1 14 Replace nuts and washers 49A B and tighten to 59 ft lbs in the pattern as shown to the right 10 REPAIR INSTRUCTIONS LP350 LP400 LP450 DISASSEMBLY OF CRANKCASE 1 2 3 4 Remove valve casing 43 and plunger pipe 29B drain oil Screw off gear cover 4 and bearing cover 14 Remove connecting rod screws 24 and push the front of connecting rod forward as far as possible Remove back halves of connecting rods note which position from which they came from Turning the crankshaft slightly carefully hit on side of crankshaft 22 with a rubber mallet until crankshaft is loose CAUTION Do not bend the connecting rod shafts Check cranshaft and connecting rod surfaces shaft seals and taper roller bearings REASSEMBLY 5 6 1 8 9 Using a soft tool press in the outer bearing ring until the outer edge lines up with the
11. ive remedy provided here under andthe 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 WAR RANTIES OR MERCHANTABILITY OR FITNESS FORA PARTICULAR PURPOSE AND ALL SUCH WARRANTIES ARE HEREBY DISCLAIMED AND EXCLUDED BY THE MANUFACTURER ur Ka 2 GIANT INDUSTRIES INC 900 N Westwood Ave P O Box 3187 Toledo Ohio 43607 E Phone 419 531 4600 FAX 419 531 6836 www giantoumps com OLITE Copyright 2002 Giant Industries Inc
12. mp Pressure as gun Rated Pressure Excessive Leakage High Crankcase Temperature 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 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 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 50hrs Every 500 hrs Recommended Spare Parts Every 1500 hrs 3000 hrs Oil Change 1 Gallon p n 1154 X X Seal Spare Parts 1 kit pump See page 7 for kit list Oil Seal Kit 1 kit pump See page 7 for kit lit Valve Spare Parts 1 kit pump See page 7 for kit list REPAIR INSTRUCTION LP350 LP400 LP450 TO CHECK VALVES 1 With a 30mm wrench 2 Remove discharge and inlet 3 With the valve assembly 46 remove the three 3 valve assemblies 46 by pointed down place a dowel
13. outer edge of the bearing hole 1 Remove the bearing cover 14 together with the shaft seal 15 and o ring 16 Fit crankshaft through bearing hole on the opposite side Press in outer bearing 20 inwards with the bearing cover 14 Make sure that the crankshaft is in a vertical position and turn it slowly so that the taper rollers of the bearings touch the edge of outer bearing ring Adjust axial bearing clearance to at least 004 and maximum at 006 by placing fitting discs 20A and or 20B under the bearing cover 14 CAUTION After assembly has been completed the crankshaft should turn easily and with very little clearance Bolt connecting rod halves together making sure they are replaced in the same position from which they came Tighten connecting rod screws to 264 in lbs 11 LP350 LP400 8 LP450 DIMENSIONS inches Outlet BSP Fitting Key 8x13 DIN 6388 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 Forportable pressure washers and car wash applications the discharge manifolds will never fail period If they ever fail we will replace them free of charge Our other pump parts used in portable pressure washers and in car wash applications are warranted for five years from the date of shipment for all pumps used in NON SALINE clean water applications 2 One 1 yea
14. 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 ob tained from the charts on pages 3 5 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 But if it is used carelessly and without regard to its potential hazard it can cause serious injury IM
15. r from the date of shipment for all other Giant industrial and consumer pumps 3 Six 6 months from the date of shipment for all rebuilt pumps 4 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 whichthe manufacturers 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 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 Repair or replacement of defective products as provided is the sole and exclus
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