Giant LP121HT User's Manual
Contents
1. 39 in seal sleeve 35 Install the complete unit in the valve casing Finally fit in the complete pump head assembly carefully over the plunger pipes and evenly tighten nuts to 59 ft Ibs To Dismantle Gear End After removing the valve casing 1 and plunger pipes 29B drain the oil Take off crankcase cover 4 and bearing cover 14 Loosen connecting rod screws 24 and push the connecting rod plunger base assembly forward as far as possible into the crosshead guides Caution Connecting rods are marked for identification Do not twist connecting rod halves Connecting rods are to be reinstalled in the same position on the crankshaft journals Turning the crankshaft 22 slightly hit it out carefully to the side with a rubber hammer Caution Do not bend the connecting rod shanks Check crankshaft and connecting rod surfaces shaft seals 15 and taper roller bearings 20 To Reassemble Using a soft tool press in the outer bearing ring until the outer edge is aligned with the outer edge of the bearing hole Take off bearing cover 14 together with shaft seal 15 and o ring 16 Fit crankshaft 22 through bearing hole on the opposite side Press in outer bearing and tension it inwards with the bearing cover keeping the shaft in a vertical position and turning 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 and a maximum of 0 15mm by placing2. accumulator may be necessary on the discharge side The pressure accumulator must be installed right behind the discharge outlet of the high pressure pump Only use one pressure accumulator in the discharge line at a time in order to avoid irritation which could be caused by different pretension levels in the accumulators Gas tension in both the inlet flow stabilizer and the pressure accumulator are to be checked regularly 26 25 LP121HT 22 97 NPSHR Ft Head 19 69 200 400 600 RPM REPAIR INSTRUCTION LP121HT PUMP To Check Valves Loosen valve plugs 48 Either with needle nose pliers or with a M12 screw which can be threaded into the hole of the spring retainer 46D take out discharge and inlet valve assemblies Press onto the valve plate 46B and twist to take apart the valve assembly Check and replace worn parts Tighten the plug to 107 ft Ibs To Check Seals and Plungers Loosen the eight nuts 49A and take off the valve casing 43 Remove the seals 40 on the valve casing Take seal sleeve 35 out of the guides in the crankcase 1 and remove the leakage seals 36 Check plunger pipes 29B for damage and remove any dirt When replacing plunger pipes use new copper rings 29D Apply loctite on threads of plunger bolts 29C and tighten to 33 ft Ibs Check seals and replace as necessary Place new v sleeves 40 along with support rings 41 in the valve casing 43 Place seals 36 and pressure rings
3. 7121 Connecting Rod Screws 310 in lbs 29C 07131 Plunger Bolt 33 ft Ibs 48 07156 Valve Plug 107 ft Ibs 49A 07158 Nut Stud Bolt 59 ft Ibs PARTS LIST LP121HT PUMP 5 Supplementary Plant Lay Out Instructions LP121HT PUMP Pressure in Inlet Side The stipulated NPSHR is the minimum required pressure above the vapor pressure of the medium and is never to fall short of this figure Temperature and vapor pressure of the medium the geodetical height of the location the flow rate and the loss of friction in the suction line must all be taken into consideration It may be necessary to install a booster pump centrifugal in the suction line Pulsation Due to its construction the plunger pump creates pulsation in the inlet and discharge lines In particular inlet pulsation must be dampened in order to prevent resonance in the suction line which in turn causes cavitation Therefore the pump is never to be connected by a rigid pipe Rather use a flexible hose which is not reinforced by steel that is 1 5 to 2 times wider than the inlet port If a booster pump is used the hose is to be attached between the booster pump and the high pressure pump If several pumps are used each pump must have its own inlet line If this cannot be done an inlet air chamber or inlet flow stabilizer must be installed in front of each pump The bladder in the stabilizer is to be pre tensioned on location Depending on the layout of the plant a pressure
4. Model LP121HT Triplex Ceramic Plunger Pump Operating Instructions Repair and Service Manual Updated 3 98 Contents Installation Instructions Pump Specifications Exploded View Parts List Kits Torque Specifications Operating Instructions Repair Instructions Dimensions Warranty Information page 2 page 3 page 4 page 5 page 5 page 6 pages 7 back page 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 installa tion 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 inclina tion 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 221 F it is important to insure a positive head to the pump to prevent cavitation See Page 6 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 t
5. NG 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 Crankcase oil should be changed after the first 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 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 Specifications LP121HT Pump Volumens Discharge Pressure nenenene Inlet Press re rn SPCC L ne Plunger Diameter eeenenene Stroke unse nein Crankcase Oil Capacity eee Temperature of Pumped Fluids Inlet Pott serien Discharge Port Crankshaft Mounting eeneneenee Shaft Rotation 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 I Select GPM r
6. R GIANT INDUSTRIES INC 900 N Westwood Avenue P O Box 3187 Toledo OH 43607 PHONE 419 531 4600 FAX 419 531 6836 www giantpumps com Copyright 1998 Giant Industries Inc
7. equired 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 EEE EEE Up to 17 6 GPM NEON RENSE ieee Up to 1200 PSI ENESTE Up to 90 PSI AEE ENE Up to 570 RPM EEE EEE ETET 36 mm DREI AERE tai 116 fl oz ME EN E E TER Up to 221 F ES 1 BSP eaan ear E aa REE 1 1 4 BSP EEE ET Either Side EEEE Top of Pulley Towards Fluid End ae EE SEN 110 Ibs HORSEPOWER INFORMATION Horsepower ratings shown are the power require ments 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 specified when selecting an electric motor as the power source To compute specific pump horsepower requirements use the following formula GPM X PSIY 1450 HP LP121HT PULLEY SELECTION AND HORSEPOWER REQUIREMENTS RPM 300 PSI 600 PSI 900 PSI 1200 PSI 20 62 13 26 38 51 500 155 32 64 96 128 3EXPLODED VIEW LP121HT EXPLODED VIEW LP121HT PUMP eh The Te ree p x we NL 4PARTS LIST LP121HT PUMPItem Part En Qty 1 07759 Crankcase jl Item Part Description Qty Item Part Description Qty 1 07759 Crankcase 1 30 13233 Flinger 3 2 13000 Oil Filler Plug Assy 1 31 06120 Seal Retainer Complete 4 06085 Crankcase Cover 1 31A 32 32A amp 33 3 5 07104 O Ring 1 31A 06118 Oil Sea
8. fitting discs 20A and 20B under the bearing cover Caution After assembly the crankshaft 22 should turn easily with very little clearance Tighten connecting rod screws 24 to 310 in Ibs NOTE Contact Giant Industries for Service School Information Phone 419 531 4600 felt OM S83 Pood ker 0 60 vw j t Cachage Cronarhor HE Tooling woes Correzione 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 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 thi
9. he 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 connec tions 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 pulsa tion 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 desig nated 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 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 OPERATI
10. l 3 6 07186 Oil Sight Glass Assy 1 32 06116 Oil Seal Retainer 3 8 06086 Oil Dipstick Assy 1 32A 06119 O Ring 3 9 01009 O Ring 1 33 06117 Backup Seal 3 10 01010 Screw 4 35 07135 Seal Sleeve 3 11 01011 Spring Washer 12 36 13291 Leakage Seal 3 12 07109 Oil Drain Plug 1 37 07139 Seal Case 3 13 07182 Gasket 1 38 07140 O Ring 6 14 07111 Bearing Cover 2 39 07142 Pressure Ring 3 15 07112 Crankshaft Seal 2 40 13199 V Sleeve 6 16 07113 O Ring 2 41 07146 Support Ring 3 17 07114 Hex Screw 8 42 07147 Tension Spring 3 20 07116 Taper Roller Bearing 2 43 13018 Valve Casing 1 20A 07117 Shim 1 3 44A 07150 O Ring 9 20B 13001 Shim 1 3 46A 07064 Valve Seat 6 21 07118 Shaft Protector 1 46B 07063 Valve Plate 6 22 07119 Crankshaft 1 46C 07062 Valve Spring 6 23 07120 Key 1 46D 07066 Spring Retainer 6 24 07121 Connecting Rod Assy 3 48 07156 Plug 3 25 07123 Crosshead Plunger 49 07157 Stud Bolt 8 Base Assy 3 49A 07158 Nut 8 28 07124 Crosshead Pin 3 49B 07159 Washer 8 29A 07125 Sleeve 3 50 07423 Plug 1 29B 07736 Plunger Pipe 3 50A 07161 Gasket 1 29C 07131 Plunger Bolt 3 52 13020 Disc for Crankshaft 1 29D 07755 Copper Gasket 3 53 13021 Hexagon Screw 1 LP121HT PUMP REPAIR KITS Plunger Packing Kit 09310 Valve Assembly Kit 09196 Qty Part No Description Qty PartNo Description 3 13291 Leakage Seal 1 07064 Valve Seat 6 07140 O Ring 1 07063 Valve Plate 6 13199 V Sleeve 1 07062 Valve Spring LP121HT PUMP TORQUE SPECIFICATIONS Position Item Description Torque Amount 24 0
11. rd party Normal wear and tear to standard wear parts Use of repair parts other than those manufactured or authorized by Giant Improper use of the product as a component part Changes or modifications made by the customer or third party The operation of pumps and or accessories exceeding the specifications set forth in the Operations Manuals provided by Giant Industries Inc OaRwWN 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 FORA PARTICULAR PURPOSE AND ALL SUCH WARRANTIES ARE HEREBY DISCLAIMED AND EXCLUDED BY THE MANUFACTURE
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