Giant LP700 User's Manual
Contents
1. 13431 13432 13020 13021 13433 13434 06272 07703 07704 DESCRIPTION Lock Pin Pressure Ring Guide Ring Sleeve Sleeve Support Ring Spring Leakage Seal O Ring Support Ring Seal Case Valve Retainer Spring Tension Cap Valve Spring Valve Plate Valve Seat O Ring Support Ring Valve Casing Stud Bolt Hexagon Nut Copper Washer Plug 1 4 Plug Cover for Valve Casing Disc for Crankshaft Hexagon Screw Hexagon Screw Plug 1 2 Copper Washer Plug 1 2 Copper Washer CP TORQUE SPECIFICATIONS Position 24 29 54 Description Connecting Rod Plunger Hexagon Screws Torque Amount 264 in lbs 22 ft Ibs 59 ft Ibs REPAIR INSTRUCTIONS Model LP700 VALVE REPLACEMENT 1 Discharge Valves Screw out 8 x hexagon screw 54 remove cover 51 Screw hexagon screw 54 into thread of plug 50 and pull out plug Using a clipring pliers remove spring tension cup 44A and valve seat 44D If necessary use a dia 12 pull out tool to remove valve seat Cheack parts and replace if worn Check O rings 40 44E and support rings 41 44F and replace as necessary Tighten hexagon screws 54 TO 59 ft Ibs Suction Valves Unscrew 8 x nut 47 remove valve casing 45 from seal sleeves 42 Using two screwdrivers lever out seal case 42 from valve casing Remove Spring tension cup 44A and valve seat 44D with a clipring pliers If necessary use a dia 12 pull out tool to remove valve seat Check p2. 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 year 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 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 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 re
3. Triplex Ceramic Plunger Pump Operating Instructions Repair and Service Manual Contents Installation Instructions page 2 Pump Specifications page 3 Exploded View page 4 Parts Kits Torque page 5 Repair Instructions page 6 Dimensions page 7 Warranty Information back page Updated 12 98 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 104 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 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
4. arts and replace if worn Check O rings 40 44E and support rings 41 44F and replace as necessary SEAL AND PLUNGER REPLACEMENT 1 2 3 4 5 Unscrew the 8 x nut 47 remove valve casing by pulling it out to the front Remove seal sleeve 35 Remove tension spring 38A and seal parts 36 38 from seal sleeve Check plunger surface and seals 37 Replace worn parts After removing clipring 32 and support ring 33 check leakage seal 33 A and replace if necessary If the surface of the plunger is worn screw out the plunger 29 with a size 13 tool Clean centring and front surface of crosshead with plunger 25 Thread new plunger carefully through oiled seals in seal sleeve Coat thread of new plunger lightly with suitable bonding agent locktite Then insert seal sleeve with plunger into crankcase guide Crank drive until plunger with crosshead 25 pushes against plunger 29 Tighten plunger 29 to 22 ft Ibs using a size 13 torque wrench NOTE The leakage seal 39 has to be installed so that its cut outs cover the 3 mm dia bores of the seal sleeves 35 as well as the 3 mm dia drip return bores of the valve casing DISASSEMBLY OF CRANKCASE 1 2 3 4 5 Remove valve casing 43 and plunger pipe 28B 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 connec
5. 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 chart on page 3 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 IMPORTANT OPERATING CONDITIONS Failure to comply with any of these conditions invalidates the warranty 1 Prior to initial operati
6. on add oil to the crank case 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 LP700 High Pressure Plunger Pump VOlUIME esa a A or Pee Pere 7 9 GPM Maximum Discharge Pressure Maximum Inlet Pressure Crankcase Oil Capacity Temperature of Pumped Fluids Up to 104 F Inlet Port 2 x 3 4 NPT Discharge Ports 2 x 1 2 NPT Shaft Rotation Either Direction 173 lbs Heich za ac a R erent terrae Ree re ee 7 92 HORSEPOWER RATINGS The rating shown are the power requirements for the pump Gas engine power outputs must be approximately twice the pump power requirements shown above LP700 HORSEPOWER CHART 3000 PSI 5000 PSI 6000 PSI 7250 PSI 8 1 13 5 16 3 19 6 9 8 16 3 19 6 23 7 11 0 18 4 22 1 26 7 13 1 219 26 3 31 7 We recommend a 1 15 service factor 14 8 24 7 29 6 35 7 be s
7. pecified when selecting an 16 5 274 32 9 39 8 electric motor as the power source To compute specific pump horse power requirements use the Follow ing formula HP GPM X PSD 1440 LP700 EXPLODED VIEW 2 Model LP700 PARTS LIST DESCRIPTION Crankcase Oil Filler Plug Assy Crankcase Cover O Ring Oil Sight Glass Oil Dipstick Assy O Ring Cylinder Screw Spring Ring Plug 1 2 Gasket Bearing Cover Radial Shaft Seal O Ring Hexagon Screw Taper Roller Bearing Fitting Disc Fitting Disc Shaft Protector Crankshaft Fitting Key Connecting Rod Assy Crosshead Plinger Assy Crosshead Pin Plunger Oil Scraper Radial Shaft Seal Clip Ring Support Disc Grooved Ring Seal Sleeve vous pee Af T w 1 1 1 1 3 3 3 3 3 3 3 3 3 3 LP700 KITS Packing Kit 09490 Oty Part 3 08087 06359 06360 13424 Description V Sleeve Pressure Ring V Sleeve Leakage Seal Valve Assembly 09491 Oty Part Description 07214 O Ring 06361 Support Ring 06362 Tension Ring 07283 Valve Spring 06363 Valve Plate 06364 Valve Seat 07035 O Ring 13427 Support Ring ANA AA a0 O ITEM 35A 36 36A 37 38 39 40 41 42 43 44A 44B 44C 44D 44E 44F 45 46 47 48 49 50 51 52 53 54 55 56 PART 22764 06359 13421 06360 13422 13423 13424 07214 06361 13425 13426 06362 07283 06363 06364 07035 13427 13428 13429 13430 07161 13261
8. quired 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 exclusive remedy provided hereunder and the MANUFACTURER SHALL NOT BE LIABLE FOR FURTHERLOSS 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 ORIMPLIED INCLUDING WITHOUT LIMITATION ANY WARRAN TIES OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE AND ALL SUCH WARRANTIES ARE HEREBY DISCLAIMED AND EXCLUDED BY THE MANUFACTURER PHONE 419 531 4600 FAX 419 531 6836 www giantpumps com Copyright 1998 Giant Industries Inc 12 98 LP700 pm6 Copyright 1998 Giant Industries Inc
9. ting 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 Check crankshaft and bearing for damage replace if needed REASSEMBLY 6 Using a soft tool press in the outer bearing ring until the outer edge lines up with the outer edge of crankcase 1 Attach bearing cover 14 with shaft seal and o ring 16 in place Fit crankshaft through bearing hole on the opposite side Press in bearing with bearing cover keeping the shaft in a horizontal position and turning it slowly so that taper rollers touch the edge of outer bearing ring Adjust axial bearing clearance to at least 004 and maximum at 006 by placing fitting discs 20A amp 20B under the bearing cover After assembly the shaft should turn easily with very little clearance Bolt connecting rod halves together making sure they are replaced in the same position from which they came from Tighten connecting rod screws to 264 in lbs Model LP700 Dimensions inches e Inlet Connection 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 For portable pressure washers and car wash applications the discharge manifolds will never fail period If they ever fail we will replace them
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