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LP460

Giant LP460 Operating Instructions/ Repair And Service Manual

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Model LP460
Triplex Ceramic
Plunger Pump
Operating Instructions/
Repair and Service
Manual
Updated 11/13
Contents:
Torque Specications: page 10
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. The pump should be installed at 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
ow rate of the pump with no unnecessary re­strictions that can cause cavitation. Teon tape
should be used to seal all joints. If pumps are to be operated at temperatures in excess of 1400 F, it is important to insure a positive head to the pump to prevent cavitation. If there is danger of frost, the water in the pump and in the pump
ttings (particularly the unloader valve) must be
emptied. Use the second discharge port and run the pump dry for 1-2 minutes.
3. The discharge plumbing from the pump should be properly sized to the ow 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 necessary to mini­mize pulsation at drive elements, plumbing, connections, 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 pulsation. 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 desig­nated 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 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
ow 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 operation, add oil to the crankcase so that oil level is between the two lines on the oil dipstick. DO NOT OVERFILL.
Use SAE 90 Industrial gear oil or Giant’s p/n 01154
Crankcase oil should be changed after the rst 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 uids 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.
2
LP460
RPM GPM 3000 PSI 4000 PSI 5000 PSI 5800 PSI
600 5.9 12.1 16.2 20.2 23.4 700 6.8 14.1 18.9 23.6 27.4 800 7.8 16.2 21.6 27.0 31.3 900 8.8 18.2 24.3 30.3 35.2
1000 9.8 20.2 27.0 33.7 39.1
LP460 Horsepower Requirements
Pump Specications
U.S. Metric
Volume..................................................................... 9.8 GPM..............................................37.0 L/min
Discharge Pressure ................................................. 5800 PSI ................................................. 400 Bar
Inlet Pressure .......................................................... -4.35 to 145 PSI .............................-0.3 to 10 Bar
Maximum Crankshaft Speed ................................................................................................1000 RPM
Plunger Diameter..................................................... 0.79”...........................................................20mm
Stroke ...................................................................... 1.65”...........................................................42mm
Crankcase Oil Capacity ........................................... 101 .oz. ......................................................3.0 L
Temperature of Pumped Fluids ............................... 104o F .......................................................... 40o C
Inlet Port ........................................................................................................................ 2 x 1-1/4” BSP
Discharge Port ..................................................................................................................... 2 x 1” BSP
Shaft Mounting .....................................................................................................................Either side
Shaft Rotation ....................................................................................... Top of pulley towards manifold
Weight ..................................................................... 128 lbs. .......................................................58 kg
Crankshaft Diameter....................................................................................................................35mm
Manifold Material .............................................................................................................Special Brass
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.
HORSEPOWER INFORMATION
Horsepower ratings shown are the power requirements 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 speci-
ed when selecting an electric motor as the power source. To compute specic pump horsepower
requirements, use the following formula:
HP = (GPM x PSI) / 1450
3
LP460 Exploded View
4
LP460 Parts List
Item Part # Description Qty.
1 07759 Crankcase 1
2 13000 Oil Filler Plug Assy. 1
3 05940 Cover Plate 1
3A 07223-0100 Spring Ring 2
3B 05051 Hexagon Screw 2
4 06085 Crankcase Cover 1
5 07104 O-Ring, Crankcase Cover 1
6 05943 Oil Sightglass with Gasket 1
8 06086 Oil Dipstick 1
9 01009 O-Ring, Dipstick 1
10 01010 Cylinder Screw 4
11 01011-0400 Spring Ring 5
12 07109 Plug 1
13 06015 O-Ring 1
14 07111 Bearing Cover 2
15 07112 Radial Shaft Seal 2
16 07113 O-Ring 2
17 07114 Hexagon Screw 8
20 07116 Taper Roller Bearing 2
20A 07117 Fitting Disc 1-3
20B 13001 Fitting Disc 1-3
Item Part # Description Qty.
29D 07258 Copper Ring 3
30 07779 O-Ring 3
31 07133 Oil Seal 3
35 04144 Seal Sleeve 3
36 07268 Pressure Ring 3
37 07322 Sleeve 3
37A 05963 Sleeve 3
38 07270 Sleeve Support Ring 3
38A 13423 Spring 3
40 04145 O-Ring 3
40A 05523 O-Ring 3
42 04146 Seal Case 3
43 13426 Valve Retainer 3
44 04263 Valve Assembly 6
44A 04119 Spring Tension Cap 6
44B 07283 Valve Spring 6
44C 04147 Valve Plate 6
44D 04121 Valve Seat 6
44E 04123 O-Ring 6
45 04148 Valve Casing 1
46 07157 Stud Bolt 8
21 05376 Shaft Protector 1
21A 05377 Shaft Guard Holder 1
22 13242 Crankshaft 1
23 13243 Woodruff Key 1
24 13340 Connecting Rod Assy. 3
24A 13277 Inner Hexagon Screw 6
24B 13278 Spring Washer 6
25 13244 Crosshead / Plunger Assy. 3
28 13232 Crosshead Pin 3
29A 07256 Centering Sleeve 3
29B 07262 Plunger Pipe 3
29C 13007 Tensioning Screw 3
47 07158 Hexagon Nut 8
47A 07159 Disc 8
48 07161 Copper Washer 1
49 07423 Plug, 1/4” BSP 1
50 04122 Valve Plug 3
51 05972 O-Ring 3
52 13020 Disc for Crankshaft 1
53 06607 Hexagon Screw 1
55 13434 Plug, 1/2” BSP 1
55A 06272 Copper Washer 1
56 07703 Plug, 3/4” BSP 1
56A 07704 Copper Washer 1
5
Preventative Maintenance Check List & Recommended Spare Parts List
Check Daily W eekly 50 hrs
Every
500 hrs
Every
1500 hrs
Every
3000 hrs
Oil Level/Quality X
Oil Leaks X
Water Leaks X
Belts, Pulley X
Plumbing X
Recommended Spare Parts
Oil Change p/n 01154 X X
Seal Spare Parts (1 kit/pump) X
Oil Seal Kit (1 kit/pump) X
Valve Spare Parts (1 kit/pump) X
LP460 Repair Kits
Plunger Packing Kit - # 09743
Item Part # Description Qty.
36 07268 Pressure Ring 3
37 07322 Sleeve 3
37A 05463 Sleeve 3
38 07270 Support Ring 3
Valve Assembly Kit - # 09744
Item Part # Description Qty.
40 04145 O-Ring 3
40A 05523 O-Ring 3
44 04263 Valve Assembly 6
Oil Seal Kit - # 09577
Item Part # Description Qty.
31 07133 Oil Seal 3
6
PUMP SYSTEM MALFUNCTION
MALFUNCTION CAUSE REMEDY
The Pressure and/ Worn packing seals Replace packing seals or the Delivery Broken valve spring Replace spring Drops Belt slippage Tighten or Replace belt Worn or Damaged nozzle Replace nozzle Fouled discharge valve Clean valve assembly Fouled inlet strainer Clean strainer Worn or Damaged hose Repair/Replace hose Worn or Plugged relief valve on pump Clean, Reset, and Replace worn parts Cavitation Check suction lines on inlet of pump for restrictions Unloader Check for proper operation
Water in crankcase High humidity Reduce oil change interval Worn seals Replace seals
Noisy Operation Worn bearings Replace bearings, Rell crankcase
oil with recommended lubricant Cavitation Check inlet lines for restrictions and/or proper sizing
Rough/Pulsating Worn packing Replace packing Operation with Inlet restriction Check system for stoppage, air Pres­sure Drop leaks, correctly sized inlet plumbing to pump Accumulator pressure Recharge/Replace accumulator Unloader Check for proper operation Cavitation Check inlet lines for restrictions and/or proper size
Pump Pressure as Restricted discharge plumbing Re-size discharge plumbing to Rated, Pressure ow rate of pump Drop at gun
Excessive Worn plungers Replace plungers Leakage Worn packing/seals Adjust or Replace packing seals Excessive vacuum Reduce suction vacuum Cracked plungers Replace plungers Inlet pressure too high Reduce inlet pressure
High Crankcase Wrong Grade of oil Giant oil is recommended Temperature Improper amount of oil in crankcase Adjust oil level to proper amount
7
LP460 REPAIR INSTRUCTIONS
To Check Valves
Discharge Valves: screw off tension plugs (50). Take the spring tension cap (44A) out of the ex-
posed discharge valve with at nose pliers.
Remove the valve seat (44D), if necessary with an M12 screw (screwing it into the M12 thread).
If the valve is extracted as a complete unity, position a screwdriver through the recess in the
spring tension cap and press down on the valve plate to gently lever the valve apart.
Check parts and replace if worn. Tighten plugs (50) at 107 ft.-lbs. (145 Nm).
Suction Valves: unscrew the 8 nuts (47) and remove the valve casing (45) from seal sleeves (35).
Using two screwdrivers, lever the seal case (42) out of the valve casing. Remove spring tension
cap with at nose pliers. Remove the valve seat (44D), if necessary with an M12 screw. Replace
worn parts.
Tighten nuts (47) evenly at 59 ft.-lbs. (80 Nm) to secure the valve casing.
To Check Seals and Plunger Pipe
Unscrew the 8 nuts (47) and remove the valve casing by pulling it off to the front. Take the seal
sleeves (35) out of their guides in the crankcase. If necessary, remove the seal case (42) from the
seal sleeve (35). Remove tension spring (38A) and seal parts (36-38) from the seal sleeve (35).
Check plunger surfaces and seals (37/37A). Replace worn parts.
If plunger pipe (29B) is worn out, loosen tension screws (29C) and pull plunger pipe off to the
front. Clean front surface of plunger (25) thoroughly.
Then place the new plunger pipe through the oiled seals (37/37A) and push seal sleeve with
plunger pipe into the crankcase guide. Turn gear until the plunger (25) comes up against the
plunger pipe.
Put a new copper gasket (29D) onto the tension screw (29C), cover the thread of the tension
screw and gasket with glue (Loctite) and tighten to 22 ft.-lbs. (30 Nm).
Important! Make sure that no glue gets between the plunger pipe (29B) and the centering sleeve
(29A). The plunger pipe should not be strained by improper tightening of the tension screw or it
may break.
Tighten nuts (47) evenly at 59 ft.-lbs. (80 Nm) to secure the valve casing.
8
LP460 REPAIR INSTRUCTIONS
To Dismantle Gear
After removing the valve casing and plunger pipes, drain the oil. Screw off gear cover (4) and bearing
cover (14).
Take off the connecting rod screws and push the front of the connecting rods as far as possible into the
crosshead guide.
Important! Connecting rods are marked for identication. Do not twist conrod halves. The conrods
must be remounted on to the shaft journals in their exact original position.
Turning the crankshaft slightly, hit it out carefully using a rubber hammer.
Important! Do not bend the conrod shanks. Check shaft and conrod mounting surfaces as well as the
shaft seal rings and roller bearings.
Reassembling
Using a soft tool, press in the outer bearing ring on one side until the outer edge lines up with the outer
edge of the bearing bore. Screw on the bearing cover together with the shaft seal and O-ring.
Insert the shaft through the bearing bore on the opposite side. Press in the outer bearing ring and x
this with the bearing cover, keeping the shaft in a vertical position and turning it slowly so that the taper
rollers of the bearings touch the edge of the outer bearing ring.
Adjust axial bearing clearance to at least 0.1mm, but less than 0.15mm by placing tting discs (20A)
under the bearing cover.
Important! After assembly has been completed, the shaft should turn easily with very little clearance.
Tighten conrod screws at 22 ft.-lbs. (30 Nm).
9
LP460 TORQUE SPECIFICATIONS
Position Item# Description Torque Amount
24A 13277 Inner Hex Screw, Connecting Rod 310 in.-lbs. (35 NM) 29C 13007 Tension Screw, Plunger 265 in.-lbs. (30 NM) 47 07158 Hexagon Nut, Stud Bolts 59 ft.-lbs. (80 NM) 48 04122 Plug, Discharge 107 ft.-lbs. (145 NM)
Pump Mounting Selection Guide
Bushings 06496 - 35 mm H Bushing
Pulley & Sheaves 07165 - 12.75” Cast Iron - 4 gr.
AB Section
Rails 07357 - Plated Steel Channel Rails
(L=11.75”x W=1.88”x H=3.00”)
10
LP460 Dimensions - inches (mm)
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. For portable pressure washers and self-serve 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 applicati ons,
are warranted for ve 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:
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 manufactured or authorized by Giant.
4. Improper use of the product as a component part.
5. Changes or modications made by the customer or third party.
6. The operation of pumps and or accessories exceeding the specications 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 work-
manship 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 war-
ranty 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 OR IMPLIED, INCLUDING WITHOUT LIMITATION ANY WAR-
RANTIES OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE AND ALL SUCH
WARRANTIES ARE HEREBY DISCLAIMED AND EXCLUDED BY THE MANUFACTURER.
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 2013 Giant Industries, Inc.
11/13 LP460.indd
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