Models P532, P533 and P536

Transcription

1 Models P532, P533 and P536 Triplex Ceramic Plunger Pump Operating Instructions/ Repair and Service Manual Updated 12/17 Contents: Installation Instructions: page 3 Pump Specifications: page 4-5 Exploded View: page 6 Parts List/Kits/Torque Specifications: page 7 Repair Instructions: page 8 Trouble Shooting Chart: page 9 Recommended Spare Parts List: page 9 Dimensions: page 10 Warranty Information back page

2 INSTALLATION INSTRUCTIONS - P532, P533 and P536 Check oil level prior to starting and ensure troublefree water supply. 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. Oil: Use only 54 ounces (1.6 litres) of SAE 80-90W 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. 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. 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. Pressure in the discharge line and pump must be at zero before any maintenance to the pump takes place. Shut off suction line. 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. 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. 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. 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

3 U.S. Measurements *Requires 15 PSI inlet pressure Pump Specifications Max. Flow Pressure Max. Speed Power Req d. Plunger Diameter Model GPM PSI RPM BHP In. In. P P * Stroke P Metric Measurements Max. Flow Pressure Max. Speed Power Req d. Plunger Diameter Model LPM Bar RPM kw mm mm P P * P Stroke Common Specifications U.S...(Metric) Temperature of Pumped Fluids...Up to 104 o F...(40 o C) Inlet Ports...2 x 1 BSP Discharge Ports...2 x 3/4 BSP Shaft Rotation...Top of pulley towards manifold Crankshaft Diameter (30 mm) Key Width (8 mm) Shaft Mounting...Either side (specify when ordering) Weight...64 lbs...(29 kg) CrankcaseCapacity...54 fl.oz....(1.6 liters) NPSHR (at ambient temperature) ft. head...(8.2 mws) 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. Materials Used: Valve Casing:...Special Brass Plungers:...Solid Ceramic Valves:...High Grade Stainless Steel Seals:...Nitrile with Fabric Reinforcing Crankshaft:...Drop Forged and case-hardenend 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 PSI) / 1450 In order to drive the pump from the side opposite the present shaft extension, simply remove the valve casing from the crankcase and rotate the pumps 180 degrees to the desired position. Be certain to rotate the seal case (item #20) as well, so that the weep holes are down at the six o clock position. Exchange the oil fill and the oil drain plugs, also. Refer to the repair instructions as necessary for the proper assembly sequence. SPECIAL NOTE: P532- The theoretical gallons per revolution (gal/rev) is To find specific outputs at various RPM, use the formula: GPM = x RPM P533- The theoretical gallons per revolution (gal/rev) is To find specific outputs at various RPM, use the formula: GPM = x RPM P536- The theoretical gallons per revolution (gal/rev) is To find specific outputs at various RPM, use the formula: GPM = x RPM 3

4 EPLODED VIEW - P532, P533 and P536 4

5 P532, P533 and P536 SPARE PARTS LIST ITEM PART DESCRIPTION QTY Crankcase, Aluminum Oil Dipstick Assembly Crankcase Cover, Aluminum O-Ring Oil Drain Plug 1 5A Gasket for Oil Drain Plug Screw 4 6A Spring Washer Bearing Cover, Aluminum 2 7A Oil Sight Glass 1 7B O-Ring 1 7C Clip Ring 1 8A Shim 1-3 8B Shim O-Ring Screw with Washer 8 10A Spring Washer Radial Shaft Seal Tapered Roller Bearing Crankshaft (P532) Crankshaft (P533) Crankshaft (P536) Fitting Key Connecting Rod Assembly 3 (P532/P533) 3 16A Plunger Pipe (P532/P533) 3 16A Plunger Pipe (P536) 3 16B Tension Screw (P532/P533) 3 16B Tension Screw (P536) 3 16C O-Ring 3 16D Support Ring 3 16E Steel Washer Crosshead w/plunger Base 3 17A Crosshead Pin Radial Shaft Seal Seal Retainer (P532/P533) Seal Retainer (P536) 3 Plunger Packing Kit (P532/P533) - #09760 Item Part # Description Qty O-Ring Sleeve Grooved Seal 3 23A Scraper 3 Plunger Packing Kit (P536) - #09753 Item Part # Description Qty O-Ring Sleeve Grooved Ring 3 23A Scraper 3 P532, P533 and P536 REPAIR KITS 5 ITEM PART DESCRIPTION QTY O-Ring Sleeve (P532/P533) Sleeve (P536) Grooved Ring (P532/P533) Grooved Ring (P536) 3 23A Scraper (P532/P533) 3 23A Scraper (P536) Sleeve Support Ring (P532/P533) Sleeve Support Ring (P536) Drip Return Ring (P532/P533) Drip Return Ring (P536) Valve Casing (P532/P533) Valve Casing (P536) Plug O-Ring Cap Screw 8 34A Vent Cap Plug, 3/4 BSP 1 36A Copper Ring Plug, 1 BSP Valve Assembly 6 46A Valve Seat 6 46B O-Ring 6 46C Valve Plate 6 46D Valve Spring 6 46E Spring Tension Cap Gear Assembly (P532) parts:1-19, Gear Assembly (P533) parts:1-19, Gear Assembly (P536) parts:1-19, Manifold Assembly (P532/P533) parts:20-46, without Manifold Assembly (P532/P533) parts:20-46, without 34 Valve Assembly Kit - #09754 Item Part # Description Qty O-Ring Valve Assembly 6 Oil Seal Kit - #09755 Item Part # Description Qty Radial Shaft Seal 3 TORQUE SPECIFICATIONS - P532, P533 and P536 Position Item# Description U.S Metric Oil Drain Plug 22 ft.-lbs. 40 Nm 6A Spring Washer 110 in.-lbs Nm Screw with Washer 132 in.-lbs. 15 Nm Screw with Washer 97 in.-lbs. 11 Nm 16B Tensioning Screw 247 in.-lbs. 28 Nm Plug 106 ft.-lbs. 145 Nm Cap Screw 59 ft.-lbs. 80 Nm

6 REPAIR INSTRUCTIONS - P532, P533 and P 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 O- rings (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). 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. 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). 6

7 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, Refill 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 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 Wrong Grade of oil Giant oil is recommended Temperature Improper amount of oil in crankcase Adjust oil level to proper amount Preventative Maintenance Check-List & Recommended Spare Parts List Check Daily Weekly 50hrs Every Every Every 500 hrs 1500 hrs 3000 hrs Oil Level/Quality Oil Leaks Water Leaks Belts, Pulley Plumbing Recommended Spare Parts Oil Change (54.1 fl.oz) p/n 1154 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) (See page 5 for kit list) 7

8 DIMENSIONS - P532, P533 and P536 - 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) or fax (419) 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 EPENSES, 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 WARRAN- TIES OR REPRESENTATION, EPRESS OR IMPLIED, INCLUDING WITHOUT LIMITA- TION ANY WARRANTIES OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE AND ALL SUCH WARRANTIES ARE HEREBY DISCLAIMED AND ECLUDED BY THE MANUFACTURER. GIANT INDUSTRIES, INC., 900 N. Westwood Ave., Toledo, Ohio PHONE (419) , FA (419) , Copyright 2017 Giant Industries, Inc. 12/17 P532_P533_P536.indd