Giant LP350 User's Manual
Contents
1. V Sleeve LP450 O Ring LP350 O Ring LP400 O Ring LP450 Pressure Spring LP400 Valve Casing O Ring Valve Assy Valve Seat Valve Plate Valve Spring Spacer Pipe Plug Stud bolt Hexagon Nut Disc Plug Copper Ring Plug Copper Ring Disc for Crankshaft Hexagon Screw SEET K REPAIR INSTRUCTION LP350 LP400 LP450 VALVE REPLACEMENT 1 With a30mm wrench remove the three 3 tension plugs 48 from top of valve casing 43 2 Remove discharge and inlet valves 46 pulling them upwards out of the valve casing It maybe necessary to use a slide hammer tool 3 With the valve assembly pointed down place a dowel rod through the top of valve cage Hold assembly in hand and tap end of dowel sharply with mallet until assembly pops free 4 Inspect valve seats 446A and valve plates H46B for damage and replace if needed 5 Check valve casing 43 surfaces for damage 6 Replace o rings 444A and reinstall valve assemblies into valve casing Lubricate o rings before installation 7 Replace tension plugs 48 and tighten them securely SEAL AND PLUNGER REPLACEMENT 1 Remove the eight 8 manifold nuts and washers 49A B using a 19mm wrench and pull off valve casing 43 If needed tap valve casing with a rubber mallet to remove it 2 Pull seal sleeve 435 out of crankcase guides 3 Remove seal case 37 from seal sleeve 4 Check plunger surface for wear and pitting If none is found proc2. 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 Up to 15 1 GPM 3600 PSI Up to 90 PSI Up to 1000 RPM 100 fl oz 140 F 1000 RPM 160 F Up to 500 RPM 1 1 4 BSP Either side Top of pulley towards manifold HORSEPOWER INFORMATION 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 PUMP MOTOR PULLEY PULLEY LP400 PULLEY SELECTION AND HORSEPOWER REQUIREMENTS GPMj2000 PSI 2500 PSI 3000 PSI 3600 PSI 12 75 3 95 12 75 13 1 15 7 18 8 12 75 12 75 Specifications Model LP450 Volume Discharge Pressure Inlet Pressure Maximum Crankshaft Speed Plunger Diameter Crankcase Oil Capacity Temperature of Pumped Fluids Discharge Port Shaft Mounting Shaft Rotation Crankshaft Diameter PULLEY INFORMATION Pulley selection and pump speed are based on a 1725 RPM motor and B section belts When selecting desired GPM allow for a
3. 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 Up to 19 7 GPM 2600 PSI Up to 90 PSI Up to 1000 RPM 100 fl oz 140 F 1000 RPM 160 F Up to 500 RPM 1 1 4 BSP Either side Top of pulley towards manifold HORSEPOWER INFORMATION 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 PUMP MOTOR PULLEY PULLEY LP450 PULLEY SELECTION AND HORSEPOWER REQUIREMENTS HPM GPM 1000 PSI 1500 PSI 2000 PSI 2600 PSI H ti zZ HE PART LP350 LP400 LP450 EXPLODED VIEW E amp n pon j gt dett cedd pa LP350 LP400 amp LP 450 PARTS LIST DESCRIPTION KA r ra M D Ohh P LA r DO DS Lol ra ra O M M M M MO MO WOW BW LA ra U W W W H lo lo lo lo lo lo IO lo ld lO lo LA gt 07759 13000 06085 07104 07186 07105 01009 01010 0101 071 0711 0711 0711 0711 0711 0
4. 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 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 GIANT INDUSTRIES INC 900 N Westwood Ave P O Box 3187 Toledo Ohio 43607 PHONE 419 531 4600 FAX 419 531 6836 www giantpumps com Copyright 1998 Giant Industries Inc Copyright 1998 Giant Industries Inc
5. 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 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 Volume Discharge Pressure Inlet Pressure Maximum Crankshaft Speed Plunger Diameter Crankcase Oil Capacity Temperature of Pumped Fluids Discharge Port Shaft Mounting Shaft Rotation Crankshaft Diameter PULLEY 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 Up to 22 6 GPM 2350 P
6. 711 0711 13001 07118 13242 13243 13340 13244 13232 07256 07261 13046 13005 13007 07258 07779 06120 06118 06116 06119 CH J Oh P ui L ra Ch M Crankcase Oil filler plug assy Crankcase Cover O ring Crankcase cover Oil Sightglass with Gasket Oil Dipstick O Ring Dipstick Cylinder Screw Spring Ring Plug Gasket Bearing Cover Radial Shaft Seal O Ring Hexagon Screw Taper Roller Bearing Fitting Disc Fitting Disc Shaft Protector Crankshaft Woodruff Key Connecting Rod Assy Crosshead Plunger Assy Crosshead Pin Centering sleeve Plunger Pipe LP350 Plunger Pipe LP400 Plunger Pipe LP450 Tensioning Screw Copper Ring O Ring Oil Seal Retainer Complete Oil Seal Oil Seal Retainer O Ring ITEM PART DESCRIPTION QTY 1 1 1 lo 0O PEPR pi o WWWWWW Lui H H Lui WwW WWW r r W Ww U WW WW WWW WwW Lu Lui OOO D GO JJ NL Li bhAA AA P Pee CO CH CH A l A U 06117 13010 13392 13009 13011 13393 07140 13012 07271 12055 13013 13016 06083 13015 07150 13394 07102 07338 13018 07150 07060 07064 07063 07062 07066 07156 07754 07158 07159 07160 0100 07161 13019 07676 13020 13021 Back Up Seal Seal Sleeve LP350 Seal Sleeve LP400 Seal Sleeve LP450 Seal Case LP350 LP450 Seal Case LP400 O Ring O Ring Pressure Ring LP350 Pressure Ring LP400 Pressure Ring LP450 V Sleeve LP350 V Sleeve LP400
7. Models LP350 LP400 LP450 Updated 3 98 Triplex Ceramic Plunger Pump Operating Instructions Repair and Service Manual Contents Installation Instructions page 2 Pump Specifications pages 3 5 Exploded View Parts page 6 Repair Instructions page 7 Kits Torque Specs 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 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 protect the pump from pressure spikes in the event of a blockage or the use of a
8. SI Up to 90 PSI Up to 1000 RPM 100 fl oz 140 F 1000 RPM 160 F Up to 500 RPM 1 1 4 BSP Either side Top of pulley towards manifold HORSEPOWER INFORMATION 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 LP350 PULLEY SELECTION AND HORSEPOWER REQUIREMENTS MOTOR PULLEY 3 95 4 95 PUMP PULLEY 12 75 12 75 RPM 500 640 GPM 11 3 14 5 2000 PSI 15 7 20 1 2300 PSI 18 0 23 1 500 PSI 1000 PSI 7 8 10 0 12 75 5 75 750 16 9 11 8 23 5 27 1 12 75 12 75 12 75 6 15 6 55 6 95 805 865 940 18 2 19 5 21 2 12 6 13 6 14 7 25 3 27 1 29 5 29 0 31 2 33 9 12 75 7 50 22 6 15 7 31 4 36 1 Specifications Model LP400 Volume Discharge Pressure Inlet Pressure Maximum Crankshaft Speed Plunger Diameter Crankcase Oil Capacity Temperature of Pumped Fluids Discharge Port Shaft Mounting Shaft Rotation Crankshaft Diameter PULLEY 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
9. acturer 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 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
10. eed to step eleven 5 If plunger 29B is worn remove tension screw 29C with a 17mm wrench Clean tension screw with wire brush to remove any old locktite 6 Discard copper gasket 29D and replace with new 7 Clean the front surface of plunger crosshead assembly 25 8 Install new plunger 29B onto plunger crosshead assembly 9 Put some locktite on both surfaces of copper gasket 29D and tension screw threads 29C 10 Secure plunger in place with tension screw 29C and gasket 29D and tighten to 33 ft Ibs 11 Remove v sleeves 40 and o ring 41 for seal case and replace with new Lubricate parts before reinstalling 12 Replace seal case 35 and seal sleeve 437 into valve casing Replace nuts and washers 49A B and tighten to 59 ft Ibs DISASSEMBLY OF CRANKCASE 1 Remove valve casing 43 and plunger pipe 28B drain oil 2 Screw off gear cover 4 and bearing cover 14 3 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 4 Turning the crankshaft slightly carefully hit on side of crankshaft 22 with a rubber mallet until crankshaft is loose 5 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 cove
11. r 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 H20A 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 LP350 LP400 amp LP450 KITS TORQUE SPECIFICATIONS Valve Kit 09196 Packing Kit LP400 09309 Qty Pat H Description Qty Pat Description Position Description Torque Amount 1 7064 Valve seat 6 06083 V sleeve 24 Connecting Rod 264 in lbs 1 7063 Valve plate 3 13349 O ring 29C Tensioning Screw 33 ft lbs 1 7062 Valve spring 3 13012 O ring 49A Hexagon Nut 59 ft lbs Packing Kit LP350 09233 3 7140 O ring Qty Pat Description 6 13016 V sleeve Packing Kit LP450 09234 3 7150 O ring Qty Part Description 3 13012 O ring 6 13015 V Sleeve 3 7140 O ring 7102 O ring 3 3 13012 O ring 3 7140 O ring LP350 LP400 amp LP 450 DIMENSIONS metric Outlet 1 BSP Scheibenfeder 813 DiN 6888 GIANT INDUSTRIES LIMITED WARRANTY Giant Industries Inc pumps and accessories are warranted by the manuf
12. 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 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 IMPORTANT OPERATING CONDITIONS Failure to comply with any of these conditions invalidates
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