Model

LP700

Triplex Ceramic

Plunger Pump

Operating Instructions/

Repair and Service

Manual

Updated 6/12

Contents:

Installation Instructions: page 2

Pump Specifications: page 3

Exploded View:

Parts, Kits, Torque:

Repair Instructions:

Dimensions: page 4 page 5 page 6 page 7

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 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 104 0 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 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 obtained 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 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 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. 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.

Use SAE 85-90W Industrial gear oil.

(or Giant’s p/n 01154)

Crankcase oil should be changed after the first 50 hours of operation, then at regular intervals of 500 hours or less depending

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.

2

Specifications

Model LP700

High-Pressure Plunger Pump

U.S. Metric

Volume................................................................. 7.9 GPM .................................. 30 L/min

Maximum Discharge Pressure ............................ 7250 PSI ....................................500 Bar

Maximum Inlet Pressure ........................................................................... -4.35 to 90 PSIG

RPM ............................................................................................................................. 1000

Plunger Diameter....................................................................................................... 18mm

Stroke ........................................................................................................................ 42mm

Crankcase Oil Capacity ....................................... 102 fl. oz. ................................ 3.5 Liters

Temperature of Pumped Fluids ........................... Up to 104 o F .................................. 40 o C

Inlet Port ..........................................................................................................2 x 3/4” BSP

Discharge Ports ...............................................................................................2 x 1/2” BSP

Shaft Rotation ............................................................................................ Either Direction 2

Weight ................................................................. 173 lbs. ......................................62.7 Kg

NPSHR ..................................................................................................................8.0 mWs

LP700 HORSEPOWER CHART

R P M G P M 3000 P S I 5000 P S I 6000 P S I 7250 P S I

500 3.9

600 4.7

700 5.3

800 6.3

900 7.1

1000 7.9

8.1

9.8

11.0

13.1

14.8

16.5

13.5

16.3

18.4

21.9

24.7

27.4

16.3

19.6

22.1

26.3

29.6

32.9

19.6

23.7

26.7

31.7

35.7

39.8

HORSEPOWER RATINGS:

The rating shown are the power requirements for the pump. Gas engine power outputs must be approximately twice the pump power requirements shown above.

We recommend 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:

HP = (GPM X PSI) / 1440

3

LP700 EXPLODED VIEW

4

12 07109

13 07182

14 07111

15 07112

16 07113

17 07114

20 07116

20A 07117

20B 13001

21 05376

21A 05377

22 13242

23 13243

24 13340

24A 13277

24B 13278

25 13341

28 13232

29 06366

30 07779

31 07133

32 06584

ITEM PART #

1

2

3

4

5

6

8

9

07759

13000

05940

3B 05051

06085

07104

07186

06086

01009

10 01010

DESCRIPTION

Crankcase

Oil Filler Plug Assy

Cover Plate

3A 07223-0100 Spring Ring

Hexagon Screw

Crankcase Cover

O-Ring

Oil Sight Glass

Oil Dipstick Assy

O-Ring

Cylinder Screw

11 01011-0400 Spring Ring

Plug 1/2”

Gasket

Bearing Cover

Radial Shaft Seal

O-Ring

Hexagon Screw

Taper Roller Bearing

Fitting Disc

Fitting Disc

Shaft Protector

Shaft Guard Holder

Crankshaft

Fitting Key

Connecting Rod Assy 3

1

1

1-3

1

1

1

8

2

2

2

Hexagon Screw

Spring Washer

Crosshead/Plinger Assy 3

Crosshead Pin

6

6

Plunger

Oil Scraper

Radial Shaft Seal

Clip Ring

3

3

3

3

3

1

2

5

1

1

4

1

1

1

1

2

2

QTY

1

1

1

LP700 PARTS LIST

ITEM PART #

33 13419

33A 08087

35 13420

35A 22764

36 06359A

36A 13421

36B 05263

37 06360

38 13422

38A 13423

39 13424

40 07214

41 06361

42 13425

43 13426

44A 06362

44B 07283

44C 06363

44D 06364

44E 07035

44F 13427

45 13428

46 13429

47 13430

48 07161

49 07423

50 13431

51 13432

52 13020

53 06607

54 13433

55 13434

55A 06272

56 07703

56A 07704

LP700 REPAIR KITS

Valve Assembly Kit

#09491

Item Part # Description

40 07214 O-Ring

41 06361 Support Ring

44A 06362 Tension Ring

44B 07283 Valve Spring

44C 06363 Valve Plate

44D 06364 Valve Seat

44E 07035 O-Ring

44F 13427 Support Ring

Plunger Packing Kit

#09736

Item Part # Description Qty.

33A 08087 V-Sleeve

36 06359A Pressure Ring

36A 13421 Guide Ring

36B 05263 Support Ring

37 06360 V-Sleeve 6

38 13422 Sleeve Support Ring 3

39 13424 Leakage Seal 3

3

3

3

3

Qty.

6

6

6

6

6

6

9

9

Oil Seal Kit

#09577

Item Part # Description

31 07133 Radial Shaft Seal

5

DESCRIPTION

Support Disc

Grooved Ring

Seal Sleeve

Lock Pin

Pressure Ring

Guide Ring

Support Ring

Sleeve

Sleeve Support Ring

Spring

Leakage Seal

O-Ring

Support Ring

Seal Case

Valve Retainer

Spring Tension Cap

Valve Spring

Valve Plate

Valve Seat

O-Ring

Support Ring

Valve Casing

Stud Bolt

Hexagon Nut

Copper Washer

Plug 1/4”

Plug

Cover for Valve Casing 1

Disc for Crankshaft

Hexagon Screw

Hexagon Screw

Plug 1/2”

Copper Washer

Plug 1/2”

Copper Washer

1

1

8

1

1

1

8

6

6

6

6

6

6

3

3

8

3

1

1

3

3

9

9

3

3

6

3

3

3

3

3

QTY

3

3

3

Qty.

3

TORQUE SPECIFICATIONS

Item Part # Description

24A

29

47

54

13277 Hexagon Screw

06366

13430

Plunger

Hexagon Nuts

13433 Hexagon Screws

Torque Amount

26 ft.-lbs. (35 Nm)

22 ft.-lbs. (30 Nm)

59 ft-lbs. (80 Nm)

59 ft.-lbs. (80 Nm)

REPAIR INSTRUCTIONS - Model LP700

VALVE REPLACEMENT

1) Discharge Valves: Screw out 8 x hexagon screw (54), remove cover (51). Screw hexagon screw (54) into thread of plug (50) and pull out plug. Using a clipring pliers, remove spring tension cap (44A) and valve seat (44D). If necessary, use a dia 12 pull-out tool to remove valve seat. Cheack parts, and replace if worn.

2) Check O-rings (40/44E) and support rings (41/44F) and replace as necessary.

3) Tighten hexagon screws (54) to 59 ft. lbs. (80 Nm).

4) Suction Valves: Unscrew 8 nuts (47), remove valve casing (45) from seal sleeves (42). Using two screwdrivers, pry out seal case (42) from valve casing. Remove Spring tension cap (44A) and valve seat (44D) with a clipring pliers. If necessary, use a 12mm pull-out tool to remove valve seat (44C). Check parts, and replace if worn.

5) Check O-rings (40/44E) and support rings (41/44F) and replace as necessary.

6) Secure valve casing (45) onto studs (46). Tighten nuts (47) to 59 ft.-lbs. (80 Nm).

SEAL AND PLUNGER REPLACEMENT

1) Unscrew the 8 x nut (47), remove valve casing by pulling it out to the front. Remove seal sleeve (35). Remove tension spring (38A) and seal parts (36-38) from seal sleeve. Check plunger surface (29) and seals (37). Replace worn parts.

2) After removing clipring (32) and support ring (33), check weep seal (33A) and replace if necessary.

3) If the surface of the plunger is worn, screw out the plunger (29) with a 13mm wrench. Clean centring and front surface of crosshead with plunger base (25).

4) Thread new plunger (29) carefully through oiled seals in seal sleeve (35). Coat thread of new plunger lightly with suitable bonding agent (locktite).

5) Then insert seal sleeve (35) with plunger (29) into crankcase guide. Turn crankshaft until plunger with crosshead (25) pushes against plunger (29). Tighten plunger (29) to 22 ft.-lbs. (30 Nm) using a 13mm torque wrench.

NOTE: The leakage seal (39) has to be installed so that its cut-outs cover the 3 mm dia. bores of the seal sleeves (35) as well as the 3 mm dia. drip-return bores of the valve casing (45).

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 cover (#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.

7) Adjust axial bearing clearance to at least .004” and maximum at .006 by placing fitting discs (#20A & 20B) under the bearing cover.

8) After assembly the shaft should turn easily with very little clearance.

9) Bolt connecting rod halves together making sure they are replaced in the same position from which they came from.

Tighten connecting rod screws to 26 ft.-lbs. (35 Nm).

6

Model LP700 Dimensions - inches (mm)

7

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 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:

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 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 2012 Giant Industries, Inc.

06/12 LP700.indd