Giant Coffeemaker LP121HT User's Manual
Contents
1. Sleeve Plunger Pipe Tensioning Screw Steel Pipe Spacer Pipe EENEG 1 3 1 1 1 3 3 3 3 3 3 3 3 Item Part 30 07779 31 07133 35 13342 0200 35A 06619 36 13415 36A 13416 0200 39 07744 0100 40 07745 41 06621 0100 42 06589 42A 07258 0100 43 13018 3000 44 07748 0300 44A 06620 45 07749 0300 46 07750 47 07752 48 06089 48A 06577 49 07157 49A 07158 49B 07159 50 07423 0100 50A 07755 0100 52 13020 53 13021 54 13321 0100 55 13322 0100 Description Oil Scraper Radial Shaft Seal Seal Sleeve O Ring Grooved Ring Pressure Ring Pressure Ring V Sleeve Support Ring Plug G 1 8 Steel Ring Valve Casing Valve Seat O Ring Valve Plate Valve Spring Spring Tension Cap Plug O Ring Stud Bolt Hexagon Nut Disc 99999999 Steel Ring Disc for Crankshaft Hexagon Screw PlugGl Plug G1 1 2 LP122A 3100 PUMP REPAIR KITS SEENEN LP122A 3100 PUMP TORQUE SPECIFICATIONS Position emt Description Torque Amount 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 va2. 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 FURTHERLOSS 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 ORIMPLIED INCLUDING WITHOUT LIMITATION ANY WARRAN TIES 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 436 PHONE 419 531 4600 FAX 419 531 6836 www giantpumps com Copyright 1998 Giant Industries Inc 3 98 LP121HT PM5
3. these conditions invalidates the warranty 1 Prior to initial operation add oil to the crank case 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 Volume Discharge Pressure Inlet Pressure Crankcase Oil Capacity Temperature of Pumped Fluids Inlet Port Discharge Port Crankshaft Mounting 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 1 Select GPM required 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 Up to 17 6 GPM Up to 1200 PSI Up to 90 PSI U
4. Triplex Ceramic Plunger Pump Operating Instructions O e Repair and Service Manual Contents Installation Instructions page 2 Pump Specifications page 3 Exploded View page 4 Parts List Kits page 5 Torque Specifications page 5 Operating Instructions page 6 Repair Instructions pages 7 Dimensions back page Updated 3 98 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 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 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 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 the pump from pressure spikes in the even
5. lve 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 lbs 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 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
6. 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 placing 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 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
7. p to 570 RPM 116 fl oz Up to 221 F 1 BSP 1 1 4 BSP Either Side Top of Pulley Towards Fluid End 110 lbs 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 PSD 1450 HP 300 PSI LP121HT PULLEY SELECTION AND HORSEPOWER REQUIREMENTS 600 PSI 900 PSI 1200 PSI eps nu Dag ayaq rd E Phi wa Ser Wr puna llaqa bg d F lt CH gt z m kal C z S Part 07759 13000 06085 07104 07186 06086 01009 08093 08094 12137 07182 07111 07112 07113 08095 07116 07117 13001 07118 13242 13243 13340 13341 28 13232 29A 07735 29B 07736 29C 07737 0100 29D 07161 0100 29E 06618 Item PARTS LIST LP122A 3100 PUMP Description Crankcase Oil Filler Plug Assy Crankcase Cover O Ring for 4 Oil Sight Glass Assey Oil Dipstick Assey O Ring for 8 Cylinder Screw Spring Ring Plug G 1 2 Gasket Bearing Cover Radial Shaft Seal O Ring for 14 Hexagon Screw Taper Roller Bearing Fitting Disc Fitting Disc Shaft Protector Crankshaft Fitting Key Conecting Rod Assey Crosshead Plunger Assy Crosshead Pin Centering
8. place 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 Defects caused by negligence or fault of the buyer or third 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 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
9. 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 Ifa 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 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 ata 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 LP121HT NPSHR Ft Head LP121HT DIMENSIONS INCHES MM x13 DN 6688 Woodrull Key Suchon Connection Cooling Woler Connections 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 Ifthey ever fail we will re
10. t 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 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
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