Giant SP100W User's Manual
Contents
1. Model SP100W Triplex Ceramic Plunger Pump Operating Instructions Repair and Service Manual Updated 8 97 Contents Installation Instructions page 2 Pump Specifications page 3 Parts List Torque Specs page A Exploded View Kits page 5 Trouble Shooting page 6 Repair Instructions page 7 Dimensions back page Warranty Information 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 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 120 F it is important to insure a positive head NPSHR FT 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 sp2. Crankcase Cover Oil Dipstick O Ring Dip Stick Oil Sight Glass Gasket Oil Sight Glass Screw Crankcase Cover Spring Washer Cover Screw Oil Drain Plug Gasket for Oil Drain Plug Bearing Cover O Ring Bearing Cover Seal Crankshaft Roller Bearing Screw amp Washer Bearing Cover Shaft Protector Crankshaft Woodruff Key Connecting Rod Assy Screw amp Washer Conn Rod Crosshead with Plunger Base Crosshead Pin Ceramic Plunger SP100W Bolt Assembly SP100W Items 24B 24C 24D 24E O Ring Bolt Assy Viton Support Ring Copper Seal Washer WwW WwW Ww YW WwwWwWwWwWwowoe F i HO WR REN eee eee ITEM PART 23 07317 Zi 08058 27A 08059 27B 08060 28 07319 29 07320 30 07335 31 07336 32 07337 33 07338 34 07325 0100 34A 07326 0100 35 07312 0100 36 07327 SC 06014 38 06015 39 07328 39A 07329 40 12057 41 07331 AIA 07213 42 07332 42A 07214 43 07333 44 07158 45 07159 46 07347 47 07344 48 07348 49 07349 DESCRIPTIONS Flinger Oil Seal O Ring Seal Housing Shim Stud Manifold SP100W Pressure Ring V Sleeve Support Ring Pressure Spring Spring Retainer Discharge Spring Retainer Inlet Valve Spring Valve Plate Valve Seat O Ring Valve Seat Valve Retainer Inlet Spacer O Ring Inlet Valve Retainer Plug Inlet Plug Discharge O Ring Inlet Plug O Ring Discharge Plug Stud Bolt Hex Nut Stud Bolt Spring Washer Stud Bolt Weep Return Plate O Ring Weep Plate Weep Retu
3. With a 22mm socket remove the three discharge 43 and three inlet 41 manifold plugs 7 Use a small slide hammer to remove valve seats 37 from manifold 29 Inspect valve plate 36 and valve seats 37 for wear If excessive pitting is seen replace the worn parts Check valve seat o ring 38 for wear and replace as neces sary NOTE Contact Giant Industries for Service School Information Phone 419 531 4600 Check o ring 44 for wear and replace as necessary Remove the discharge spring retainer 34 valve spring 35 and valve plate 36 Drain the oil from the pump Turn the pump over to remove the four manifold stud nuts 46 with a 19mm wrench The front oil seal 31A can now be removed by inserting a screwdriver through the rear of the retainer and tapping the seal out through the front of the retainer Remove any ex cess old loc tite from retainer To replace oil seal apply a light film of loc tite around outside edges of seal Tap seal firmly into the retainer with a wooden dowel making certain that the spring side of the seal is installed first and that the seal sits squarely in the re tainer SP100W DIMENSIONS 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 Five 5 years from the date of shipment for all pumps used in portable pressure washers
4. 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 OR IMPLIED INCLUDING WITHOUT LIMITATION ANY WAR RANTIES OR MERCHANTABILITY OR FITNESS FORAPARTICULAR PURPOSE AND ALL SUCH WARRANTIES ARE HEREBY DISCLAIMED AND EXCLUDED BY THE MANUFACTURER 8 97 SP100 PM5
5. with NON SALINE clean water applications Two 2 years from the date of shipment for Giant pumps used in car wash 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 whichthe 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 1 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 AReturned 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
6. 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 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 ol in crankcase PUMP SYSTEM MALFUNCTION 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 pump for restrictions Check for proper operation Reduce ol change interval Replace seals Replace bearings Refill crankcase oil with recommended lubricant Check inlet lines for restrictions and or proper sizing Replace 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 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 REPAIR INSTRUCTION SP100W SERIES 1
7. 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 INFORMATION Horsepower ratings shown are the power require ments for the pump Gas engine power outputs must be approximately twice the pump power require ments 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 GPM X PSI 1460 HP SP100W PULLEY SELECTION amp HORSEPOWER REQUIREMENTS 9 75 4 15 700 55 45 57 72 75 9 75 PUMP MOTOR PULLEY PULLEY RPM GPM 1200 PSI 1500 PSI 1900 PSI 2000 PSI 9 9 75 5 25 900 71 58 73 92 97 9 75 5 50 950 75 61 77 97 102 9 75 9 75 9 75 9 75 1 2 8 2 2 9 ITEM PART 1 07294 2 07295 2A 07296 3 07297 4 07298 5 07299 6 01009 7 07186 8 07187 9 01010 10 01011 11 07109 11A 07182 12 07302 13 07303 14 07459 15 07306 16 07114 17 07308 18 13349 19 07252 20 07310 21 07311 22 07315 23 07314 24A 07346 24B 07360 24C 07023 24D 07203 24E 07258 SP100W PARTS LIST DESCRIPTIONS Crankcase Oil Filler Cap Gasket Oil Filler Cap Cover Crankcase O Ring
8. ikes 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 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 But if it is used carelessly and without regard to its potential hazard it can cause serious injury IMPORTANT OPERATING CONDITIONS Fa
9. ilure 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 SAE 80W 140 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 SP100W Ke ut E Discharge E Ire tt Maximum Speed of Crankshaft Plunger HEE EE SLC ene eee ne geet Crankcase Oil Capacity 00 cceee Temperature of Pumped Fluids Inlet 20 i keene ne ere ee eee Discharge EE Crankshaft Mounting 0 0 cceee Shaft AR Ol AULOM E ebe Up to 11 2 GPM E Up to 2000 PSI E Up to 90 PSI EE Up to 1420 RPM E 26mm AE Up to 160 F ee 2 3 4 NPT eege 2 3 8 NPT EE Either Side EE Top of Pulley Towards Fluid End Se 31 Ibs PULLEY INFORMATION Pulley selection and pump speed are based on a 1725 RPM motor and B section belts When selecting desired GPM
10. rn Seal Seal Support Ring Earlier non weep versions only had an oil seal They did not have items 27 27A and 27B Position 24B Alor 41A A4 07331 or 07213 SP100W TORQUE SPECIFICATIONS Part Description 07360 Tension Screw 07158 Plug Inlet and Discharge Nut Stud Bolt Torque Amount 228 in lbs 103 ft Ibs 52 ft lbs SEENEN SP100W EXPLODED VIEW SP100W REPAIR KITS Plunger Packing Repair 09077 Qty Part 3 07336 Description V Sleeve Ceramic Plunger Kit 09079 Part 07346 07360 07317 LA WW Weep Repair Kit Qty Part l 07344 Plate 3 07348 Description Ceramic Plunger Bolt Assy 24B E Flinger 09075 Description O Ring Weep Return Seal Weep Return oe H Part 07326 0100 07312 0100 07327 06014 06015 12057 07332 nlet Valve Kit 09069 Description Inlet Spring Retainer Valve Spring Valve Plate Valve Seat O R ng Valve Seat O Ring Inlet Valve Retainer O Ring Inlet Plug Discharge Valve Kit 09068 07325 0100 07312 0100 07327 06014 06015 Description Discharge Plug O Ring Spring Retainer Discharge Valve Spring Valve Plate Valve Seat O Ring Valve Seat MALFUNCTION The Pressure and or the Delivery Drops Water in crankcase Noisy Operation Rough Pulsating Operation with Pressure Drop Pressure Drop at Gun Excessive Leakage High Crankcase Temperature CAUSE Worn packing seals
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