Giant Router LP122A-3100 User's Manual
Contents
1. 17 07114 0100 20 07116 20A 07117 20B 13001 21 07118 22 13242 23 13243 24 13340 25 1334 28 13232 29A 07735 29B 07736 29C 07737 0100 29D SPARE PARTS LIST LP122A 3100 PUMP DESCRIPTION Crankcase Oil Filler Plug Crankcase Cover O Ring Oil Sight Glass W Gasket Oil Dipstick O Ring Screw Spring Washer Oil Drain Plug Gasket Bearing Cover Crankshaft Seal O Ring HexScrew Taper Roller Bearing Fitting Disc 0 1mm Fitting Disc 0 15mm Shaft Protector Crankshaft Key Connecting Rod Assy Crosshead Plunger Base Assy Crosshead Pin Centering Sleeve Plunger Pipe Plunger Bolt 07161A 0100 Gasketfor Bolt Plunger Kit 09575 Item Qty Part Description 35A 3 06619 O Ring 36 3 13145 Grooved Ring 39 3 07744 0100 Pressure Ring 40 6 07745 Sleeve Oil Seal Kit 09577 Item Qty Part Description 31 3 07133 QTY CONN NRK OH BR Fei Fesch Fei Fesch T by N 1 3 p pih Oo U LA UUU UW ke ITEM PARTNO 29E 06618 30 07779 31 07133 35 13342 0100 35A 06619 36 13415 36A 13416A 0100 36B 06174 39 07744 0100 40 07745 4 07746 0100 43 13018 3000 A 07748 0300 44A 06620 45 07749 0300 46 07750 46A 07751 0100 47 07752 48 06089 48A 06577 49 07157 49A 07158 49B 07159 50 07423 0100 50A 07755 0100 52 13020 SE 06607 54 13321 0300 55 13322 0300 LP122A 3100 Repair Kits Valve Assembly Kit Radial Shaft Seal DESCRIPTION Spacer Pipe Flinge2. Mode LP122A 3100 Triplex Ceramic Plunger Pump Operating Instructions Repair and Service Manual Updated 11 06 Contents Installation Instructions page 2 Pump Specifications page 3 Exploded View page 4 Parts List Kits page 5 Repair Instructions pages 6 8 Trouble Shooting page 9 Recommended Spare Parts List page 10 Torque Specifications page 10 Pump Mounting Selection Guide page 10 Dimensions page 11 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 160 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 Itis essential to provide a safety byp
3. 52 6 kg Crankshaft Diameter eenegen Eeer eege 35mm Valve Casing LP122A 3100 sacs cicartossvententonesinercdanlacciaciiccssowepacsstacasndsioasaaiet Aluminum Bronze Nickle Vol metric Eficieney T S00 RPM eege 0 96 Mechanical Efficiency 800 RPM eeeseeesssssssssssssssssssserrseerrressssssssssss 0 85 PULLEY INFORMATION HORSEPOWER INFORMATION Pulley selection and pump speed are based on a 1725 We recommend that a 1 1 service factor be specified RPM motor and B section belts When selecting when s electing an electric motor as the power source desired GPM allow for a 5 tolerance on pumps To compute specific pump horsepower requirements output due to variations in pulleys belts and motors use the following formula among manufacturers 1 Select GPM required then select appropriate HP GPM X PSI 1440 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 Pump speeds of 640 RPM and above require a minimum inlet pressure of 12 psig LP122A 3100 PULLEY SELECTION AND HORSEPOWER REQUIREMENTS PUMP MOTOR PULLEY PULLEY GPM 600 PSI 800 PSI 1000 PSI 1300 PSI 2000 PSI 12 75 3 95 223 500 96 127 159 207 319 Exploded View LP122A 3100 ITEM PARTNO 07759 2 13000 4 06085 5 07104 6 07186 8 06086 9 01009 10 01010 0400 11 08094 12 07109 0400 13 07182 14 07111 15 07112 16 07113
4. 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 REPRESENTA TION 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 Avenue P O Box 3187 Toledo OH 43607 PHONE 419 531 4600 FAX 419 531 6836 www giantpumps com Copyright 2006 Giant Industries Inc 11 06 LP122A 3100 PMD
5. ass 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 guide lines available upon request from Giant Industries Inc Required horsepower for system operation can be obtained from the charts on pages 3 6 Before beginning operation of your pumping system remember Check that the crankcase and seal areas have been properly lubricated per recom mended 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 itis used carelessly and without regard to its potential hazard i
6. he center of the four 4 pieces so that the threaded end is exposed Apply several drops of loc tite 243 or equivalent adhesive to the threads Thread into steel plunger base and tighten to 26 ft lbs BE CERTAIN ALL PARTS ARE CENTERED WITH THE BOLT 9 Lubricate weep seal 36 Place weep seal 36 and pressure ring 36A 10 Place support ring 41 and into the seal sleeve 35 Assemble the o ring 35A onto seal sleeve and v sleeves 40 into valve lubricate casing LP122A 3100 Repair Instructions 11 Press seal sleeve assembly into 12 Place entire manifold seal De Teen EE the manifold and seat firmly sleeve assembly over the studs crosswise pattern shown Put the support ring 41 on and push firmly until seated above to 60 ft Ibs plunger with v side facing the against the crankcase ee manifold 16 Fill crankcase with approxi mately 116 fluid ounces of G1 ant oil or equivalent SAE 90 industrial gear oil and check oil level of the crankcase with the dipstick Proper level is center of two lines Reinstall your Gi ant LP pump into your system 14 Next place valve assemblies 15 Replace plug with o ring 48 amp 46A into manifold after first 48A and tighten to 160 ft Ibs lubricating the o ring 44A Seat firmly into manifold Contact Giant Industries or your local distributor for maintenance of the gear end of your pump Phone 419 531 4600 Contact Giant Industries for service school info
7. or restrictions and or proper size Re size discharge plumbing to Flow Rate of Pump Replace plungers Adjust or Replace packing seals Reduce suction vacuum Replace plungers Reduce inlet pressure Giant oil is recommended Adjust oil level to proper amount Preventative Maintenance Check List amp 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 Oil Change 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 LP122A 3100 TORQUE SPECIFICATIONS Position ltem Description Torque Amount 10 08093 Screw Cover 125 in lbs 17 08095 Hex Screw Bearing Cover 125 in lbs 24A 13277 Hex Screw Connecting Rod 250 in lbs 29C 07131 0100 Plunger Bolt 26 ft lbs 48 06077 0100 Plug Valve 160 ft Ibs 49A 07158 Nut Stud Bolt 60 ft lbs Pump Mounting Selection Guide Bushings 06496 35mm H Bushing Pulley amp Sheaves 07165 12 75 Cast Iron 4 gr AB Section Rails 07357 Plated Steel Channel Rails L 11 75 xXW1 88 xH 3 00 10 LP122A 3100 DIMENSIONS INCHES mm Key AflxBx5 DIN 6685 Blatt 2 3 60 1 4 Bag CO ZU We 368 ki i 6 3 160 Centering 15 385 2 0 520 5 123 14 345 s Sege Pons X d 2 51 3 2 51 1 6 41 5 4
8. r Radial Shaft Seal Seal Sleeve O Ring Grooved Ring Pressure Ring Drip Shield Pressure Ring Sleeve Support Ring Valve Casing Valve Seat O Ring Valve Plate Valve Spring Valve Assy Complete Spring Tension Cap Plug O Ring Stud Bolt Nut Washer Plug Gasket Disk for Crankshaft Hexagon Screw Plug 1 BSP Plug 1 BSP Q E EE EE EE ee ee 09576 Item Qty Part Description 44 6 07748 0300 Valve Seat 44A 6 06620 O Ring 45 6 07749 0300 Valve Plate 46 6 07750 Valve Spring 47 6 07732 Spring Tension Cap 48A 6 06736 O Ring LP122A 3100 Repair Instructions With a 30mm wrench re move the six 6 plugs 48 from the valve casing 43 Inspect the o rings 48A and replace if necessary Remove the complete valve assembly 46A by thread ing a 12mm bolt into the spring retainer and pulling straight out To disassemble the valve screw the bolt into the retainer until the valve plate 45 presses the valve seat 44 out of the spring retainer Examine all parts and replace if necessary If the seat doesn t come out use a valve puller to remove Remove the eight 8 hex nuts 49A with a 19mm wrench Tap the back of the manifold 43 with a rubber mallet to dislodge and slide off the studs Remove the seal sleeve 35 from the manifold and or crankcase Remove the pressure rings 39 amp 36A v sleeves 40 amp 36 support ring 41 and o rings 35A from the manifold and seal sleeve re
9. rmation Phone 419 531 4600 MALFUNCTION The Pressure and or the Delivery Drops Water in crankcase Noisy Operation Rough Pulsating Operation with Pressure Drop Pump Pressure as Rated Pressure Drop at Gun Excessive Leakage High Crankcase Temperature CAUSE 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 pump for restrictions Unloader High humidity Worn seals Worn bearings oil with Cavitation Worn packing Inlet restriction Accumulator pressure Unloader Cavitation Restricted discharge plumbing Worn plungers Worn packing seals Excessive vacuum Cracked plungers Inlet pressure too high Wrong Grade of oil Improper amount of oil in crankcase PUMP SYSTEM MALFUNCTION REMEDY 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 Check for proper operation Reduce oil change interval Replace seals Replace bearings Refill crankcase recommended lubricant Check inlet lines for restrictions and or proper sizing Replace packing Check system for stoppage air leaks correctly sized inlet plumbing to pump Recharge Replace accumulator Check for proper operation Check inlet lines f
10. spectively Examine seals care fully and replace if worn Clean all parts LP122A 3100 Repair Instructions 5 If there are signs of oil leaking through the plunger oil seals then replacment is neccessary Remove the plunger pipe 29B before inspect ing oil seals 31A A 33 Dissassemble the gear end and push out the seals from the back of the pump 6 Inspect surface of plunger pipe 29B carefully Remove any chemical or mineral deposits taking care not to damage the surface of the plunger If plunger pipe is worn remove the plunger bolt 29C plunger pipe 29B and spacer 29E Replace worn parts necessary Note Always use a new copper gasket 29 when repairing the plunger assem 7 Oil seal replacement can be 8 If previously disassembled thoroughly clean all exposed surfaces on the accomplished by pulling the spacer 29E and all exposed threads on the plunger bolt 29C and the retainer forward out of the steel plunger base 25 Threads MUST be free of old loc tite and any crankcase The o ring around other material such as oil grease etc This is necessary to ensure proper the outside of the retainer should be replaced and lubri cated with a light film of oil curing of new loc tite Giant recommends cleaning the threads with acetone or other suitable cleaner Reassemble plunger assembly parts 29A 29B amp 29E using a new copper gasket 29D and the cleaned plunger bolt 29C Slide the bolt through t
11. t 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 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 80 90W Industrial Gear Lube Oil p n 3 Acids alkalines or abrasive fluids cannot be pumped 01154 unless approval in writing is obtained before operation from Giant Industries Inc 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 4 Run the pump dry approximately 10 seconds to drain the water before exposure to freezing temperatures NOTE Contact Giant Industries for Service School Information Phone 419 531 4600 2 Specifications Model LP122A 3100 L O Metric Volume eegene 35 6 GPM 134 7 l m Discharge EE ee 1300 PS banse 90 Bar EE 90 go oreste 6 2 Bar EL gt EE Up to 800 RPM Plonger Diametef enee LOS er 42 mm el LO waecresess 42 mm Crankcase Oil Capacity E 116 de EE 3 43 liters Temperature Of Pumpe d FIGS eccssisdcnasevdinassvisscanssesnanases eren ae Malot POT E 1 1 2 BSP Diren e PO EE 1 BSP Crankshaft Ce Either Side AEG I OU O E Top of Pulley Towards Fluid End EE 116lbs
12. x Di Inlet Ports 8 3 210 2 x 1 1 2 BSP 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 dateof 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
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