Models P540 and P541

Models P540 and P541
Models
P540 and P541
Triplex Ceramic
Plunger Pump
Operating Instructions/
Repair and Service Manual
Contents:
Installation Instructions:
Pump Specifications:
Exploded View:
Parts List/Kits/Torque Specifications:
Repair Instructions:
Trouble Shooting Chart:
Recommended Spare Parts List:
Dimensions:
Warranty Information
page 3
page 4-5
page 6
page 7
page 8
page 9
page 9
page 10
back page
INSTALLATION INSTRUCTIONS - P540 AND P541
Check oil level prior to starting and ensure troublefree water supply.
Pressure in the discharge line and pump must be
at zero before any maintenance to the pump takes
place. Shut off suction line.
Important!
If there is a danger of frost, the
water in the pump and in the pump fittings (particularly the unloader valve) must be emptied. The
second discharge port can also be used and the
pump run “dry” for 1-2 minutes for this purpose.
Disconnect fuses to ensure that the driving motor
does not get switched on accidently.
Make sure that all parts on the pressure side of
the unit are vented before starting the pump. In
order to prevent air, or an air-water-mixture being
absorbed and to prevent cavitation occurring, the
pump NPSHR (=suction head) and water temperature must be respected.
Oil: Use only 54.1 ounces (1.6 litres) of SAE 8090W gear oil (p/n 01154).
Initial oil change after 50 operating hours and then
every 1000 hours, after 1 year if used less.
Caution: When operating in damp places or
with high temperature fluctuations, oil must be
changed immediately (should condensation or
frothy oil occur in the gear case).
NPSH values must be observed.
Max. input pressure 145 PSI (10 bar), max. suction head -4.4 PSI (-0.3 bar). Make sure that the
suction pulsation is sufficiently dampened - water
column resonance must be avoided.
Cavitation and/or compression of gases lead
to uncontrollable pressure-kicks which can
ruin pump and unit parts and also be dangerous to the operator or anyone standing nearby.
GIANT Plunger Pumps are suitable for pumping
clean water and other non-aggressive or nonabrasive media with a specific weight similar to
water.
Important!
If the pump is not used for a long
period of time, it is possible the seals (22 & 23)
could become hard or brittle thus causing the
pump to leak when put into operation.
If this is the case, we recommend these seals be
replaced every 4 years.
Before pumping other liquids - especially flammable, explosive and toxic media - the pump
manufacturer must be consulted with regard
to the resistance of the pump material. It is
the responsiblity of the equipment manufaturer and/or operator to ensure that all pertinent
safety regulations are adhered to.
!
ΔSafety
Rules
A safety valve is to be installed in accordance with
the guidelines for liquid spraying units so that the
admissible operating pressure cannot be exceeded by more than 10%. Pump operation without a
safety valve as well as any excess in temperature
or speed limits automatically voids the warranty.
When the pump is in operation, the drive shaft end
and the coupling must be enclosed by a protective
cover or a coupling bell.
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.
2
Specifications
Models P540 and P541
U.S........................... (Metric)
Volume..........................................................35.4 GPM ................ (134 LPM)
Discharge Pressure.......................................1450 PSI.................. (100 bar)
Speed (Continuous)....................................................................... 1450 RPM
Inlet Pressure (maximum).............................-4.35 to145 PSI ....... -0.3 to 10 bar
Plunger Diameter..........................................1.57”......................... 40 mm
Crankshft Stroke............................................1.02”......................... 26 mm
Crankshaft Diameter...................................................................... 35 mm
Crankshaft Mounting...................................................................... Either side
Shaft Rotation................................................................................. Top of pulley towards manifold
o
o
Temperature of Pumped Fluids.....................Up to 104 F ............ (40 C)
Inlet Ports....................................................................................... (2) 1-1/2” BSP
Discharge Ports.............................................................................. (2) 1” BSP
Weight (P540)................................................91.5 lbs. ................... (41.5 kg)
Weight (P451)................................................84.9 lbs..................... (38.5 kg)
Crankcase Oil Capacity.................................54.1 fl. oz.................. (1.6 liter)
Fluid End Material (P540)............................................................... Forged Brass
Fluid End Material (P541)............................................................... Nickel-Plated Spheroidal Cast Iron
Consult the factory for special requirements that must be met if the pump is to operate beyond one or more of the limits specified above.
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 1.15 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) / 1450 = HP
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.
P540 and P541 Horsepower Requirements
RPM GPM
500
PSI
750
PSI
1000
PSI
1250
PSI
1450
PSI
725
17.7
6.1
9.2
12.2
15.3
17.7
800
19.5
6.7
10.1
13.5
16.8
19.5
900
22.0
7.6
11.4
15.2
19.0
22.0
1000
24.4
8.4
12.6
16.8
21.0
24.4
1200
29.3
10.1
15.2
20.2
25.3
29.3
1450
35.4
12.2
18.3
24.4
30.5
35.4
Materials Used:
Plungers........ Solid Ceramic Oxide
Valves............ Stainless Steel
Seals............. Nitrile with Fabric Reinforcing
Gear End....... Die-Cast Aluminum
3
EXPLODED VIEW - P540 and P541
4
P540 and P541 SPARE Parts List
ITEM
1
2
3
4
5
5A
6
6A
7
7A
7B
7C
8A
8B
9
10
10A
11
12
13
14
15
16
16A
16B
16C
16D
16E
17
17A
19
19A
20
PART
04405
04234
04406
04407
07109
06015
01010
01011-0400
04408
08490
08492
04237
04409
04410
04411
07114
01011
04238
04239
04425
04241
04242
04427
04428
08399
07023
07203
07258
04412
07124
07624
04413
04429
DESCRIPTION
QTY.
Crankcase
1
Oil Dipstick Assembly
1
Crankcase Cover
1
O-Ring
1
Oil Drain Plug
1
Gasket for Oil Drain Plug 1
Screw
4
Spring Washer
4
Bearing Cover 1
Oil Sight Glass
1
O-Ring
1
Clip Ring
1
Shim
1-3
Shim
1
O-Ring
2
Screw with Washer
8
Spring Washer
8
Radial Shaft Seal
1
Tapered Roller Bearing
2
Crankshaft
1
Fitting Key
1
Connecting Rod Assembly 3
Plunger Assembly
3
Plunger Pipe
3
Tension Screw
3
O-Ring
3
Support Ring
3
Steel Washer
3
Crosshead w/Plunger Base 3
Crosshead Pin
3
Radial Shaft Seal
3
Distance Ring
3
Seal Retainer
3
ITEM
21
22
23
23A
24
25
26
26
32
33
34
34A
36
36A
37
46
46A
46B
46C
46D
46E
47
47A
47B
47C
47D
47E
PART 06560
05308
04430
04431
04432
04433
04434
04458
04435
12055
05546
04417
12449
13372-0300
04436
04437
13304
12055
13306
13307
13308
04438
13304
12055
13306
04439
13308
04400
04441
04442
DESCRIPTION
QTY.
O-Ring
3
Sleeve
6
Grooved Ring
3
Scraper
3
Sleeve Support Ring
3
Drip Return Ring
3
Valve Casing (P540)
1
Valve Casing (P541)
1
Plug
6
O-Ring
6
Cap Screw
8
Cap
2
Plug, 1” BSP 1
Copper Ring
1
Plug, 1-1/2” BSP
1
Inlet Valve Assembly
3
Valve Seat
3
O-Ring
3
Valve Plate
3
Inlet Valve Spring
3
Spring Tension Cap
3
Discharge Valve Assembly 3
Valve Seat
3
O-Ring
3
Valve Plate
3
Discharge Valve Spring
3
Spring Tension Cap
3
Gear Assy. (1-19, 34)
Manifold Assy. (20-47 w/out 34)
Manifold Assy. (20-47 w/out 34)
P540 and P541 REPAIR KITS
Plunger Packing Kit - #09776
Item
21
22
23
23A
Part #
06560
05308
04430
04431
Description
O-Ring
Sleeve
Grooved Seal
Scraper
Inlet Valve Assembly Kit - #09777
Item
33
46
Part # Description
12055 O-Ring
04437 Inlet Valve Assembly
Discharge Valve Assembly Kit - #09778
Qty
3
6
3
3
Item
33
47
Part # Description
12055 O-Ring
04438 Valve Assembly
Oil Seal Kit - #09755
Item
19
Qty
3
3
Part # Description
07624 Radial Shaft Seal
Qty
3
3
Qty
3
TORQUE SPECIFICATIONS - P540 and P540
Position
15
16B
32
34
Item#
04242
08399
04435
05546
Description
Screw with Washer
Tensioning Screw
Plug
Cap Screw
5
U.S
97 in.-lbs.
248 in.-lbs.
107 ft.-lbs.
59 ft.-lbs.
Metric
11 Nm
28 Nm
145 Nm
80 Nm
REPAIR INSTRUCTIONS - P540 and P541
1. To Check Valves
Screw out plugs (32) with a socket wrench.
Remove the exposed spring tension cap (46E)
from the valve seat by pushing it sideways using
a screwdriver. Remove spring tension cap, valve
spring (46D) and valve plate (46C). Pull out valve
seat (46A) with a valve puller. Examine valve
components for wear and damage. Check Orings (46B). Replace worn parts.
Pay attention to the sequence of installation when
reassembling. New O-rings should be coated with
oil.
Tighten plungs (32) to 107 ft.-lbs. (145 Nm).
Important! Be careful not to scratch the
valve casing.
Carefully push the whole pump head over the
ceramic plungers and against the crankcase.
Tighten hexagon socket screws (34) evenly in a
crosswise manner at 59 ft.-lbs. (80 Nm).
3. Drive
If oil leaks where the plunger (17) protrudes out of
the drive, gear seals (19) and plungers must be
examined and replaced as necessary.
Remove oil plug (5) and drain oil; remove crankcase cover (3).
Remove valve casing (26), seal casing (21), seal
adaptors (20) as well as plunger pipes (16A) as
desribed in point 2.
Take off screws on connnecting rods (15), seperate the back connecting rod half from the crankshaft and front connecting rod half by screwing a
screw into the center back bore on the connecting
rod.
Be careful not to mix up the connecting rod
halves.
Push conrod shaft as far as possible into the
crosshead guide.
Take off screws (10) and remove bearing covers
(7) with the help of a screwdriver.
Take out crankshaft carefully threading it through
the conrods (15), making sure not to bend the
conrods. Remove and dismantle conrods and
plungers (17) paying attention not to damage the
plungers.
Lever out gear seal (19) using a screwdriver.
To reinstall, press the gear seal (19) into the drive
casing first. Then insert conrods with plungers.
Thread in crankshaft. Mount bearing covers (7)
together with the taper roller bearing (12) and fix
with screws (10).
Mount bearing cover (8) and adjust clearance by
fitting shims (8A/8B) under the bearing cover (8)
to ensure the crankshaft turns easily without play
being felt.
Finally, mount conrod halves together and tighten
screws (15) at 97 in.-lbs. (11 Nm). Mount crankcase cover (3) together with O-ring (4).
When remounting the valve casing, tighten hexagon socket screws at 59 ft.-lbs. (80 Nm).
2. To Check Seals and Plunger Pipes
Remove hexagon socket screws (34) and pull off
valve casing (26) to the front. Pull seal retainers (20) out of the valve casing (26) or crankcase
(1). Examine O-rings (21), grooved rings (23) and
scraper (23A).
Remove drip return rings (25), V-sleeves (22) and
support rings (24) from the valve casing. Check
that the bores in the leakage rings and the corresponding bores in the valve casing are free of
obstruction.
Check plunger surfaces (16A). Damaged surfaces cause accelerated seal wear. Lime and
other deposits on the plunger must be carefully
removed using a sharp knife. Be careful not to
damage plunger surfaces. If plunger pipe (16A)
is worn, remove tensioning screw (16B) with the
plunger. Examine and clean the plunger mounting
surface (17), check and mount the new plunger
pipe.
Lightly coat the threads of the tensioning screw
(16B) with Loctite and carefully tighten to 248
in.-lbs. (28 Nm). Glue must never come between
plunger pipe (16A) and centering sleeve (16F).
The plunger pipe should not be strained by extensive tightening of the tension screw or through
damage to the front surface as this can lead to
breakage.
When reassembling, insert scraper (23A) and
grooved ring (23) into seal retainer (20).
Carefully push the whole unit onto the ceramic
plunger (if necessary use the drip return ring to
hold the grooved ring in its seal retainer) and push
it down into the crankcase fitting. Slide on drip return ring (25) with its V-profile facing upwards. Put
sleeve support ring (24) into the valve casing. Tilt
V-sleeve (22) into its fitting. Then carefully press it
level using the flat side of a screwdriver.
6
PUMP SYSTEM MALFUNCTION
MALFUNCTION
CAUSE
REMEDY
The Pressure and/
Worn packing seals
or the Delivery
Broken valve spring
Drops
Belt slippage
Worn or Damaged nozzle
Fouled discharge valve
Fouled inlet strainer
Worn or Damaged hose
Worn or Plugged relief valve on pump
Cavitation
pump for restrictions
Unloader
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 Water in crankcase
Reduce oil change interval
Replace seals
High humidity
Worn seals
Check for proper operation
Noisy Operation
Worn bearings
Cavitation
Replace bearings, Refill crankcase oil with recommended lubricant
Check inlet lines for restrictions
and/or proper sizing
Rough/Pulsating
Worn packing
Operation with
Inlet restriction
Pressure Drop
Accumulator pressure
Unloader
Cavitation
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
Pump Pressure as
Restricted discharge plumbing
Re-size discharge plumbing to Flow
Rated, Pressure
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
Temperature
Wrong Grade of oil
Improper amount of oil in crankcase
Giant oil is recommended
Adjust oil level to proper amount
Preventative Maintenance Check-List & Recommended Spare Parts List
Check
Daily Weekly 50hrs
Every
500 hrs
Oil Level/Quality
X
Oil Leaks
X
Water Leaks
X
Belts, Pulley
X
Plumbing
X
Recommended Spare Parts
Oil Change (54 ounces) p/n 1154
X
X
Seal Spare Parts (1 kit/pump)
(See page 5 for kit list)
Oil Seal Kit (1 kit/pump)
(See page 5 for kit lit)
Valve Spare Parts (1 kit/pump)
Every
1500 hrs
Every
3000 hrs
X
X
X
(See page 5 for kit list)
7
DIMENSIONS - P540 and P541 - INCHES (MM)
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-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 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 con
sumer 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 modifications made by the customer or third party.
6. 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. 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 or implied, including without limitation any warranties 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 2015 Giant Industries, Inc.
08/15 P540_P541.indd
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