Giant LP1000 User Manual

Model LP1000

Triplex Ceramic
Plunger Pump
Operating Instructions/
Repair and Service
Manual

Updated 9/00

Contents:

Installation/Repair
Instructions: pages 2-7
Exploded View: page 8
Parts List / Kits: page 9
Torque Specifications: page 9
Pump Specifications: page 10
Pump Dimensions: page 11
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 installation. If you 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 crank­shaft.

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 be observed to ensure that gear parts are properly lubricated.

1.1.1 Hydraulic Connections

a.) Inlet Line

· On both sides of the pump head there is one ½ suction port and one 3/8 discharge port. Non-required portholes can

be closed with the supplied plugs and bonding agent.

· Suction and discharge connections are to be fitted with elastic tubes to damp vibrations and guard the pump against

pipeline tensions.

· 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 is 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.

· 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 head,
the suction line should be thoroughly rinsed before being fixed to the suction port.

b.) Discharge Line

· Tubes, pipes and fittings of the discharge line must have a safety factor well above the maximum operating pressure.

· 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.

· An air vent should be built into the discharge line as near as possible to the pump.

· 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.

· The discharge line is to be laid either horizontally or rising steadily away from the pump.

· Return-flow lines from unloader valves and safety valves must be connected to the feed tank, never directly to the

suction port.

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.

NOTE: Contact Giant Industries for Service School Information. Phone: [phone]

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Hydraulic System Set Up

Intake

Feed Tank

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

Bypass Return

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 accumulator 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

· Check pump oil level and if necessary 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.).

· Start the pump and let it run in pressure-free bypass operation for approx. 2 minutes to enable the automatic functioning

seal cooling system to 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 a result 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.)

· 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.

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4. Maintenance and 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 before reassembling.

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.

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