Giant LP1000 User's Manual
Contents
1. Updated 9 00 Triplex Ceramic Plunger Pump Operating Instructions Repair and Service Contents Installation Repair Instructions Exploded View Parts List Kits Torque Specifications Pump Specifications Pump Dimensions Warranty Information Model LP1000 pages 2 page 8 page 9 page 9 page 10 page 11 back page INSTALLATION INSTRUCTIONS Installation of the Giant Industries Inc pump is not a complicated procedure but there are some basic steps common toall pumps The following information is to be considered as a general outline for installation Ifyou have unique requirements please contact Giant Industries Inc or your local distributor for assistance 1 Set Up and Installation The pump is to be mounted horizontally onto a solid frame that is also to accommodate the drive motor The place of installation has to be chosen so that the belt drive and pump are made easily accessible for maintenance work oil dip stick and oil filler plug must also be easy to reach 1 1 Pump Important The preferred drive form is with toothed belts Bare V belts are admissible if the exact required belt tension can be kept Excessive belt tension can lead to increased heating of the drive system and can even lead to breakage of the crank shaft Important The direction of rotation of the pump is indicated by an arrow on both bearing flanges situated of the crankcase The indicated direction of rotation must be2. Filler Plug Assy l 36A 06586 Plug Crankcase Cover 1 37A 06587 Elbow for Rinsing Pipe O Ring for Cover l 37B 06588 Screw in Pipe Connection Oil Sight Glass l 37C 06589 Plug G 1 8 c w Hexagon Oil Dipstick Assy l 37D 07258 0100 Steel Washer O Ring for Oil Dipstick l 38 06590 Sleeve Support Ring Cylinder Screw 4 39 06591 Spiral Ring Spring Ring 5 40 06592 Support Ring Plug G 1 2 l 41 06593 Seal Tension Spring Gasket l 42 06594 Spring Tension Ring Bearing Cover 2 43 06595 Border Seal Ring Radial Shaft Seal 2 4A 06596 Drip Return Ring O Ring for Bearing Cover 2 45 06560 O Ring Hexagon Screw 8 46 06597 Seal Case Taper Roller Bearing 2 47 07740 O Ring Fitting Disc 1 3 48 07750 Valve Spring Fitting Disc 1 3 49 06598 Inlet Valve Plate Shaft Protector 1 50 06599 Valve Body Crankshaft l 51 12092 O Ring Fitting Key l a2 06600 Support Ring for item 5 1 Connecting Rod Assy 3 53 06601 Border Seal Ring Crosshead Plunger Assy 2 54 06602 Valve Casing Crosshead Pin 3 55 06603 Spring Guide Plunger Assembly 2 56 12090 Valve Spring Oil Scraper 3 57 06604 Discharge Valve Plate Radial Shaft Seal 3 58 06605 Stud Bolt Clip Ring 3 59 06606 Hexagon Screw Support Disc 3 60 13020 Disc for Crankshaft Grooved Ring 3 6l 06602 Hexagon Screw LP1000 KITS Seal Repair Kit Valve Repair Kit 09517 09518 Qty Part Description Qty Part Description 3 07391 Grooved Ring 3 07750 Valve Spring 3 06590 Sleeve Support Ring 3 06598 Inlet Valve Plate 3 06591 Spiral
3. observed to ensure that gear parts are properly lubricated 1 1 1 Hydraulic Connections a Inlet Line e On both sides of the pump head there is one 2 suction port and one 3 8 discharge port Non required portholes can be closed with the supplied plugs and bonding agent e Suction and discharge connections are to be fitted with elastic tubes to damp vibrations and guard the pump against pipeline tensions e The diameter of the suction line must be at least one size bigger than the suction inlet port Important The pump is not to be connected directly to the water mains as gas bubbles present in fresh water can lead to premature wear and destruction of seals and valves A feed tank with a volume at least 5 times greater than the pump discharge rate per minute 16 to be installed The feed tank must be fitted with baffle plates to stop any air coming into the tank from passing on through the suction port e The necessary input pressure of 36 0 PSI 2 5 Bar bar must be guaranteed using a centrifugal pump A filter max particle size 50 micron with a volume at least 3 times greater than the pump discharge rate per minute must be fitted between the centrifugal pump and high pressure pump To check the required input pressure we recommend the installation of a pressure gauge between the filter and high pressure pump Important All fittings must be tightly fixed to avoid air entering into suction line To avoid dirt entering into the pump he
4. 600 FAX 419 531 6836 www giantpumps com Copyright 2000 Giant Industries Inc 9 2000 LP1000 PM6
5. OlOSUUOD 1 141 SE Gir 91 080 SI S002 9 sge 21 001 Ce 010 909 091 069 8 Si c 00z 6 2 688 SISL 09 9 lt CEE NIO 8W SO SED CED Wi HUN MIQ OSX8XOLV 49 11 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 self service 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 carwash applications are warranted for five years from the dateof 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 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 LA 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 1 Defects caused by negligence or fault of the buyer or third party 2 Normal wear and tear to standard wear parts 3 Use of repair parts other than those manufa
6. Ring 3 06599 Valve Body 3 06595 Border Seal Ring 3 12092 O Ring 6 06560 O Ring 3 06600 Support Ring for O Ring 3 07740 O Ring 3 06601 Border Seal Ring 3 06603 Sping Guide 3 12090 Valve Spring 3 06604 Discharge Valve Plate LP1000 TORQUE SPECIFICATIONS ltem Description Torque Amount 13340 Connecting Rod Assy 26 ft lbs 13341 Crosshead Plunger Assy 33 ft lbs 06606 Hexagon Screw 59 ft lbs a ae os Ws ee an ae epee eo ee Specifications Model LP1000 High Pressure Plunger Pump ie 1 arse scence E A E EEEE E E EE E 3 4 GPM 12 8 LPM Ee EE EE 14 500 PSI 1000 Bar ENN Inlet PPC SS E Up to 90 PSIG 1305 Bar REM eege 1000 Eer Dne ee 22mm EE 42mm Crankcase Oil Capacity eege 118 fl oz 3 5 Liters Temperature of Pumped Regie g eegesgeeange esgCoegtogk Egger eege Up to 104 F 40 C le PON A cnc sere E N E 2 x 1 2 BSP Dae EE 2 x 3 8 BSP no TEN Oe E O ME Towards fluid end only KE E 143 Ibs 65 KG LP1000 HORSEPOWER CHART HORSEPOWER RATINGS RPM GPM 7250 PSI 10 000 PSI 12 500 PSI 14 500 PSI The rating shown are the power requirements for the pump Gas engine power outputs must be approximately twice the pump power requirements shown above 1000 We recommend a 1 15 service factor be specified when selecting an electric motor as the power source To compute specific pump horse power requirements use the Follow ing formula HP GPM X PSI 1400 10 LP1000 DIMENSIONS mm 012 908 U
7. ad the suction line should be thoroughly rinsed before being fixed to the suction port b Discharge Line e Tubes pipes and fittings of the discharge line must have a safety factor well above the maximum operating pressure e A suitable safety valve must be installed immediately after the initial length of flexible discharge line There are to be no shut off valves between the pump and safety valve e An air vent should be built into the discharge line as near as possible to the pump e The most optimal place for installing a pressure gauge is between the pump and safety valve The second outlet on the pump casing can also be used for this purpose e The discharge line is to be laid either horizontally or rising steadily away from the pump e Return flow lines from unloader valves and safety valves must be connected to the feed tank never directly to the suction port NOTE Contact Giant Industries for Service School Information Phone 419 531 4600 2 Hydraulic System Set Up Intake Feed Tank f 2 A 4 3 6 f T f Ss SOLO Lem lt or Bypass Return 1 Coarse Filter 5 LP1000 High pressure pump 2 Booster pump 6 High pressure gauge 3 Fine particle filter 7 Excess Safety valve 4 Gauge to check input pressure 2 2 Pressure Accumulator The purpose of the pressure accumulator if installed is to damp pulsation from the high pressure pump and thus avoid vibrations in the discharge line Gas in the pressure a
8. ccumulator should be pretensioned to 50 60 of the maximum operating pressure The correctly pretensioned gas must be checked regularly approx every 2 months see separate operating instructions for pressure accumulator if necessary 3 Operation Operation and Maintenance e Check pump oil level and ifnecessary fill up refer to specification information on page 8 First oil change to be made after 50 hours of operation thereafter oil must be changed every 500 operating hours or at least every 6 months whichever comes first Caution when operating in damp places or with high temperature fluctuations Oil must be changed immediately should condensate frothy oil occur in the gear end Before the high pressure pump is started the centrifugal pump must produce the min intake pressure of 36 0 PSI 2 5 Bar Open discharge line e g spray gun to enable booster pump to vent the system Open all regulator valves and other shut off agents Activate bypass system or switch pressure regulating valve to bypass to enable pressure free start Start motor briefly to check the direction of rotation Pay careful attention to the direction of rotation that is specified for the pump arrows indicated on crankcase To serve this purpose the pump must only be dry run for a short period approx 30 sec e Start the pump and let it run in pressure free bypass operation for approx 2 minutes to enable the automatic functioning seal cooling system t
9. ctured or authorized by Giant 4 Improper use of the product as a component part 5 Changes or modifications made by the customer or third party 6 Theoperation of pumps andor 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 replacementor 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 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 ORIMPLIED INCLUDING WITHOUT LIMITATION ANY WARRANTIES OR MERCHANTABILITY OR FITNESS FORAPARTICULAR PURPOSE ANDALL SUCH WARRANTIES ARE HEREBY DISCLAIMED AND EXCLUDED BY THE MANUFACTURER GIANT INDUSTRIES INC 900 N Westwood Avenue P O Box 3187 Toledo OH 43607 PHONE 419 531 4
10. e reassembling cm 57 Inlet Valves Remove inlet valve spring 48 with valve plate 49 from seal case 46 Check sealing surfaces of the valve plate 49 and valve body 50 Check O rings 47 51 and support ring 52 before reassemble Worn parts must be replaced To Check Seals and Plungers Unscrew hexagon screw 59 and take off valve casing 54 Remove the screw in joints 37B and take off the elbow pipes 37A Remove drip return ring 44 from seal sleeve 36 Then pull seal sleeve 36 out of the crankcase Take the seal tension spring 41 out of seal sleeve 36 Using pliers remove the clip ring 32 situated on the other side of the sleeve then take out support ring 33 and grooved ring 35 using an extractor tool 12 O14 or 16 as per plunger Using a seal extractor tool 012 4 014 4 or 516 4 as per plunger carefully press the seal unit comprising of guide ring 38 spiral ring 39 and supporting ring 40 out of the seal sleeve 36 from the side 36 closest to the drive Check spiral ring 39 guide ring 38 and grooved ring 35 and replace where necessary 42 Check surface of plunger 29 for damage A worn plunger 29 must be screwed out key size 22 and replaced Due to reasons of precision the ceramic plunger alone cannot be exchanged Coat the threads of the plunger lightly with an appropriate bonding agent and tighten plunger to 33 Ft lbs 45Nm Important C
11. heck the leakage bores 4 of the seal sleeves 36 and seal cases 46 for dirt and clean if necessary The elbow screw in joints 37B and elbow pipes 37A must also be checked for dirt and cleaned if necessary Important The 4 leakage bore of the middle seal sleeve must be closed by a rubber plug 36A to ensure water circulation from seal sleeve 1 to seal sleeve 3 Fit the drip return unit 32 33 35 the high pressure seal unit 38 39 40 and tension spring 41 into the seal sleeve Then push the assembled seal sleeves 36 carefully onto the plungers and into the drive thereafter mount elbow pipes 37A as per the exploded view and tighten the screw in joints 37B carefully Check O rings on the drip return ring 45 as well as border seal ring 43 and replace where necessary Push the valve casing 54 with its seal cases 46 and drip return rings 44 onto the seal sleeves 36 Tighten valve casing nuts 59 evenly to 59 ft lbs 80 N M To Dismantle Gear First disassemble valve casing and seal sleeves then screw out oil plug 12 and drain oil Thereafter screw off gear cover 4 and bearing cover 14 Remove connecting rod conrod screws and push the front of the conrod parts forward as far as possible into the crosshead guide Important Conrods are marked for identification Do not twist conrod halves When reassembling conrods are to be fitted back onto the shaft journals in their exact original positi
12. o vent itself Important A small portion of water from the suction chamber which runs through the seal sleeves and steel elbow pipes is led off to pass behind the high pressure seals to cool these As aresult of heat dissipation the elbow pipes are approx 41 50 F 5 10 C warmer than the water temperature on the suction side Important Check regularly to ensure elbow pipes do not overheat If pipes become very hot indication of seal wear stop pump immediately and examine seals and plungers see maintenance section e Listen carefully for an even running sound If the pump begins to run irregularly or pulsate strongly it can be that one of the three plungers is not vented In this case the pump should be started and stopped at quick intervals to ease venting Venting is also made easier if the vent tap in the discharge line is opened 3 4 Maintenanceand Repair To Check Valves Discharge Valves Screw out hexagon screws 59 and remove valve casing 54 Pull seal case 46 out of valve casing 54 Pull valve body 50 and seal case 46 apart Using pliers pull spring guide 55 out of the valve casing Remove discharge valve plate 57 together with spring 56 from spring guide 55 Check sealing surfaces of the valve body 50 and discharge valve plate 57 Check discharge valve spring 56 and border seal ring 53 and replace where necessary Important A damaged border seal ring 53 must be replaced befor
13. on Turning the crankshaft gently tap it out carefully to one side using a rubber hammer Important Do not bend conrod shafts Check the running surface of the shaft and conrods as well as the shaft seal rings and tapered roller bearings To Reassemble Gear End Using a soft tool press in outer bearing ring on one side of the crankcase until its outer edge sits evenly on the bearing bore Then screw on bearing cover together with shaft seal ring and O ring Insert shaft through the bearing hole on the opposite side Press in outer bearing ring and tension inwards with bearing cover keeping the shaft in vertical position and turning it slowly so that the tapered rollers of the bearing sit evenly on the outer bearing ring Adjust axial bearing clearance to at least 0 1mm and maximum 0 15mm by placing fitting discs 20A under one of the bearing covers Important After assembly has been completed the shaft should turn easily with very little clearance Tighten conrod screws to 26 Ft lbs 35 Nm Model LP1000 Exploded View ITEM PART 20A 20B 21 23 24 25 28 29 30 31 32 33 35 07759 13000 06085 07104 07186 06086 01009 01010 01011 07109 07182 07111 07112 07113 07114 07116 07117 13001 07118 13242 13243 13340 13341 13232 06583 07779 07133 06584 06610 07391 Position 24 25 59 Model LP1000 PARTS LIST DESCRIPTION QTY ITEM PART DESCRIPTION Crankcase l 36 06585 Seal Sleeve Oil
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