Triplex Ceramic
Plunger Pump
Operating Instructions/
Repair and Service
Manual
Model
SP100W
Contents:
Installation Instructions:
Pump Specifications:
page 2
page 3
Parts List/Torque Specs.: page 4
Exploded View / Kits:
Trouble Shooting:
Repair Instructions:
Dimensions:
page 5
page 6
page 7
back page
Warranty Information:
back page
Updated 8/97
Download from Www.Somanuals.com. All Manuals Search And Download.
Specifications
Model SP100W
Volume........................................................................................................ Up to 11.2 GPM
Discharge Pressure ..................................................................................... Up to 2000 PSI
Inlet Pressure .............................................................................................. Up to 90 PSI
Maximum Speed of Crankshaft.................................................................. Up to 1420 RPM
Plunger Diameter........................................................................................ 26mm
Stroke.......................................................................................................... 20mm
Crankcase Oil Capacity .............................................................................. 24 fl.oz.
Temperature of Pumped Fluids .................................................................. Up to 160 oF
Inlet Ports ................................................................................................... (2) 3/4" NPT
Discharge Ports .......................................................................................... (2) 3/8" NPT
Crankshaft Mounting.................................................................................. Either Side
Shaft Rotation................................................................................ Top of Pulley Towards Fluid End
Weight......................................................................................................... 31 lbs.
Crankshaft Diameter................................................................................... 28mm
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.
PULLEY INFORMATION
HORSEPOWER INFORMATION
Pulley selection and pump speed are based on a 1725 Horsepower ratings shown are the power require-
RPM motor and "B" section belts. When selecting ments for the pump. Gas engine power outputs must
desired GPM, allow for a ±5% tolerance on pumps be approximately twice the pump power require-
output due to variations in pulleys, belts and motors ments shown above.
among manufacturers.
1. Select GPM required, then select appropriate when selecting an electric motor as the power source.
motor and pump pulley from the same line. To compute specific pump horsepower requirements,
2. The desired pressure is achieved by selecting the use the following formula:
We recommend that a 1.1 service factor be specified
(GPM X PSI) / 1460 = HP
correct nozzle size that corresponds with the pump
GPM.
SP100W PULLEY SELECTION & HORSEPOWER
REQUIREMENTS
PUMP MOTOR
PULLEY PULLEY
RPM GPM 1200 PSI 1500 PSI 1900 PSI 2000 PSI
9.75"
9.75"
9.75"
9.75"
9.75"
9.75"
9.75"
9.75"
4.15"
4.70"
5.25"
5.50"
5.80" 1000 7.9
6.90" 1200 9.4
7.45" 1300 10.2
8.10" 1420 11.2
700 5.5
800 6.3
900 7.1
950 7.5
4.5
5.2
5.8
6.1
6.5
7.7
8.4
9.2
5.7
6.5
7.3
7.7
8.1
9.7
10.5
11.5
7.2
8.2
9.2
7.5
8.6
9.7
10.2
10.8
12.9
14.0
9.7
10.2
12.3
13.3
14.5
Download from Www.Somanuals.com. All Manuals Search And Download.
SP100W PARTS LIST
ITEM PART
DESCRIPTIONS
Crankcase
Oil Filler Cap
Gasket, Oil Filler Cap
Cover, Crankcase
O-Ring, Crankcase Cover
Oil Dipstick
O-Ring, Dip Stick
Oil Sight Glass
Gasket, Oil Sight Glass
Screw, Crankcase Cover
Spring Washer, Cover Screw
Oil Drain Plug
Gasket for Oil Drain Plug
Bearing Cover
O-Ring, Bearing Cover
Seal, Crankshaft
Roller Bearing
Screw & Washer,
Bearing Cover
Shaft Protector
Crankshaft
Woodruff Key
Connecting Rod Assy.
Screw & Washer, Conn. Rod
Crosshead with Plunger Base
Crosshead Pin
Ceramic Plunger, SP100W
Bolt Assembly, SP100W
(Items 24B, 24C, 24D, 24E)
O-Ring, Bolt Assy. (Viton)
Support Ring
QTY ITEM PART
DESCRIPTIONS
Flinger
Oil Seal
O-Ring
Seal Housing
Shim, Stud
Manifold, SP100W
Pressure Ring
V-Sleeve
Support Ring
Pressure Spring
QTY
3
3
3
3
2
1
3
3
3
3
3
3
6
6
6
6
3
3
3
3
3
3
3
4
4
4
1
1
3
3
1
2
2A
3
4
5
6
7
8
07294
07295
07296
07297
07298
07299
01009
07186
07187
01010
01011
07109
07182
07302
07303
07459
07306
07114
1
1
1
3
1
1
1
1
1
4
4
2
2
2
2
2
2
25
27
27A
27B
28
29
30
31
32
33
34
34A
35
36
37
38
39
07317
08058 1
08059
08060
07319
07320
07335
07336
07337
07338
9
10
11
11A
12
13
14
15
16
07325-0100 Spring Retainer, Discharge
07326-0100 Spring Retainer, Inlet
07312-0100 Valve Spring
07327
06014
06015
07328
07329
12057
07331
07213
07332
07214
07333
07158
07159
07347
07344
07348
07349
Valve Plate
Valve Seat
O-Ring, Valve Seat
Valve Retainer, Inlet
Spacer
O-Ring, Inlet Valve Retainer
Plug, Inlet
39A
40
41
41A
42
42A
43
44
45
46
6
1
1
1
3
3
3
3
3
17
18
19
20
21
22
23
24A
24B
07308
13349
07252
07310
07311
07315
07314
07346
07360
Plug, Discharge
O-Ring, Inlet Plug
O-Ring, Discharge Plug,
Stud Bolt
Hex Nut, Stud Bolt
Spring Washer, Stud Bolt
Weep Return Plate
O-Ring, Weep Plate
Weep Return Seal
Seal Support Ring
47
3
3
3
3
48
49
24C
24D
24E
07023
07203
07258
Copper Seal Washer
1
Earlier (non-weep) versions only had an oil seal. They did not have items 27, 27A and 27B.
SP100W TORQUE SPECIFICATIONS
Position
24B
Part#
07360
Description
Tension Screw
Torque Amount
228 in.-lbs.
41 or 41A
44
07331 or 07213
07158
Plug, Inlet and Discharge
Nut, Stud Bolt
103 ft.-lbs.
52 ft.-lbs.
Download from Www.Somanuals.com. All Manuals Search And Download.
SP100W EXPLODED VIEW
SP100W REPAIR KITS
Plunger Packing Repair #09077
Qty. Part # Description
07336 V-Sleeve
Inlet Valve Kit #09069
Qty. Part # Description
3
3
3
3
3
3
3
3
07326-0100 Inlet Spring Retainer
07312-0100 Valve Spring
Ceramic Plunger Kit
Qty. Part #
#09079
Description
07327
06014
06015
12057
07332
Valve Plate
Valve Seat
O-Ring, Valve Seat
O-Ring, Inlet Valve Retainer
O-Ring, Inlet Plug
3
3
3
07346
07360
07317
Ceramic Plunger
Bolt Assy. (24B-E)
Flinger
Weep Repair Kit #09075
Qty. Part # Description
O-Ring,Weep Return
Discharge Valve Kit
#09068
Qty. Part #
Description
1
07344
07348
3
3
3
3
3
3
07214
Discharge Plug O-Ring,
Plate
3
07325-0100 Spring Retainer, Discharge
07312-0100 Valve Spring
07327
06014
06015
Seal, Weep
Return
Valve Plate
Valve Seat
O-Ring, Valve Seat
Download from Www.Somanuals.com. All Manuals Search And Download.
PUMP SYSTEM MALFUNCTION
CAUSE
MALFUNCTION
REMEDY
Worn packing seals
Broken valve spring
Belt slippage
Worn or Damaged nozzle
Fouled discharge valve
Fouled inlet strainer
Worn or Damaged hose
Worn or Plugged relief valve on pump
Cavitation
The Pressure and/
or the Delivery
Drops
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
pump for restrictions
Check for proper operation
Unloader
High humidity
Worn seals
Water in crankcase
Noisy Operation
Reduce oil change interval
Replace seals
Worn bearings
Cavitation
Replace bearings, Refill crankcase
oil with recommended lubricant
Check inlet lines for restrictions
and/or proper sizing
Worn packing
Inlet restriction
Rough/Pulsating
Operation with
Pressure Drop
Replace packing
Check system for stoppage, air
leaks, correctly sized inlet
plumbing to pump
Accumulator pressure
Unloader
Cavitation
Recharge/Replace accumulator
Check for proper operation
Check inlet lines for restrictions
and/or proper size
Restricted discharge plumbing
Pressure Drop at
Gun
Re-size discharge plumbing to
flow rate of pump
Worn plungers
Excessive Leakage
Replace plungers
Worn packing/seals
Excessive vacuum
Cracked plungers
Inlet pressure too high
Adjust or Replace packing seals
Reduce suction vacuum
Replace plungers
Reduce inlet pressure
Wrong Grade of oil
Improper amount of oil in crankcase
High Crankcase
Temperature
Giant oil is recommended
Adjust oil level to proper amount
Download from Www.Somanuals.com. All Manuals Search And Download.
REPAIR INSTRUCTION - SP100W SERIES
41A
44
34
35
36
1. With a 22mm socket, remove
the three discharge (43) and
three inlet (41) manifold plugs.
2. Check o-ring (44) for wear and replace as necessary. Remove the
discharge spring retainer (34), valve spring (35), and valve plate (36).
7. Use a small slide hammer to
remove valve seats (37) from
manifold (29). Inspect valve
plate (36) and valve seats (37)
for wear. If excessive pitting
is seen, replace the worn parts.
Check valve seat o-ring (38)
for wear and replace as neces-
sary.
firmly into the retainer with a
wooden dowel making certain
that the spring side of the seal
is installed first and that the
seal sits squarely in the re-
tainer.
8. Drain the oil from the pump.
Turn the pump over to remove
the four manifold stud nuts
(46) with a 19mm wrench.
9. The front oil seal (31A) can
now be removed by inserting a
screwdriver through the rear
of the retainer and tapping the
seal out through the front of
the retainer. Remove any ex-
cess old loc-tite from retainer.
To replace oil seal, apply a
light film of loc-tite around
outside edges of seal. Tap seal
NOTE: Contact Giant Industries for Service School Information. Phone: (419)-531-4600
Download from Www.Somanuals.com. All Manuals Search And Download.
SP100W DIMENSIONS
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. Five (5) years from the date of shipment for all pumps used in portable pressure
washers with NON-SALINE, clean water applications.
2. Two (2) years from the date of shipment for Giant pumps used in car wash applications.
3. One (1) year from the date of shipment for all other Giant industrial and consumer
pumps.
4. Six (6) months from the date of shipment for all rebuilt pumps
5. Ninety (90) days from the date of shipment for all Giant accessories.
Thiswarrantyislimitedtorepairorreplacementofpumpsandaccessoriesofwhichthe 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-
RANTIESORMERCHANTABILITYORFITNESSFORAPARTICULARPURPOSEANDALLSUCH
WARRANTIES ARE HEREBY DISCLAIMED AND EXCLUDED BY THE MANUFACTURER.
8/97 SP100.PM5
Download from Www.Somanuals.com. All Manuals Search And Download.
|