Giant LP121A-5100, LP200-5100, LP250-5100 Operating Instructions/ Repair And Service Manual

Triplex Ceramic Plunger Pump Operating Instructions/ Repair and Service
Models
Manual
LP121A-5100/LP200-5100/LP250-5100
updated 02/19
Contents:
Installation Instructions: page 2 LP200-5100/LP121A-5100 Specs: page 3 Exploded View / Kits: page 4 Parts List: page 5 LP250-5100 Specs: page 6 Repair Instructions: page 7-9
Torque Specications: page 9
Pump Mounting Selection Guide: page 9 Troubleshooting: page 10 Recommended Spare Parts List: page 10 Dimensions: page 11 Warranty Information: back page
INSTALLATION INSTRUCTIONS
Operation and Maintenance
Check oil level prior to starting and ensure trouble free water supply.
IMPORTANT! If there is a danger of frost,
the water in the pump and in the pump ttings
(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 118 uid ounces (3.5 L) of SAE
90 Industrial gear lube oil. (Giant’s p/n 01154)
Initial change after 50 operating hours and then every 1000 operating hours, or after one year if used less.
Caution! When operating in damp places or with high temperature uctuations, conden­sate (frothy oil) might occur in the gear box. In this situation, change the oil immediately.
Keep NPSH under control.
Maximum input pressure is 145 PSI (10 bar), the maximun suction head is -4.35 PSI (-0.3 bar). Make sure that suction pulsation is suf-
ciently dampened. Water column resonance
must be avoided.
Safety Rules
Pump operation without safety valve as well as any excess in temperature or speed limits automatically voids the warranty. The safety valve must be regulated in accordance with the guidelines for liquid spraying units so that the admissible operating pressure can not be exceeded by more than 10%.
When the pump is in operation, the open shaft end must be covered up by a shaft protector (21). For direct drive operations, the driven shaft side and coupling must have a guard over the connected area.
Pressure in discharge line and in pump must be at zero before any maintenance to the
pump takes place. Close the uid supply to
the inlet port(s). Disconnect fuses to ensure that the driving motor does not accidentally get switched on. Make sure that all parts on the pressure side of the unit are vented and re-
lled, with pressure at zero, before starting the
pump.
In order to prevent air, or air/water mixture being absorbed and to prevent cavitation oc­curring, the pump-npshr, positive suction head and water temperature must be kept under control.
Required NPSH refers to water: Specic
weight 0.0624 lb/ft3 (1kg/dm3), viscosity 1°E at maximum permissible revolutions.
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 pumps are suitable for pumping clean water and other non-aggressive or abrasive
media with a specic weight similar to water.
Before pumping other liquids - especially
inammable, explosive and toxic media -
the pump manufacturer must under all cir­cumstances be consulted with regard to the resistance of the pump material. It is the re­sponsibility of the equipment manufacturer and/or operator to ensure that all pertinent safety regulations are adhered to.
NOTE: Contact Giant Industries for Service School Information. Phone: (419)-531-4600
2
Model LP200-5100 Specications
U.S Metric
Volume ..........................................................................................19.1 GPM ..................................... 72.2 LPM
Discharge Pressure ...................................................................... 3000 PSI ......................................... 200 Bar
Inlet Pressure ............................................................................... -4.35 to 87 PSI ...................... -0.3 to 6.0 Bar
Speed ...................................................................................................................................... Up to 1000 RPM
Plunger Diameter .......................................................................... 1.10” .................................................. 28 mm
Stroke ............................................................................................ 1.65” .................................................. 42 mm
Crankcase Oil Capacity ................................................................ 118 .oz. ................................................ 3.5 L
Temperature of Pumped Fluids @ 1000 RPM ............................... 140 o F ................................................. 60 oC
Temperature of Pumped Fluids @ 500 RPM ................................. 160 o F ..................................................70 oC
Inlet Port .................................................................................................................................... (3) x 1-1/2” BSP
Discharge Port ................................................................................................................................. (3) x 1” BSP
Crankshaft Mounting ......................................................................................................................... Either Side
Shaft Rotation .................................................................................................... Top of Pulley Towards Fluid End
Weight .......................................................................................... 119 lbs. ................................................ 54 kg
Crankshaft Diameter ................................................................................................................................ 35 mm
Model LP121A-5100 Specications
U.S Metric
Volume ..........................................................................................32.5 GPM ................................... 123.1 LPM
Discharge Pressure ...................................................................... 1740 PSI .......................................... 120 Bar
Inlet Pressure ............................................................................... -4.35 to 87 PSI .......................-0.3 to 6.0 Bar
Speed ...................................................................................................................................... Up to 1000 RPM
Plunger Diameter .......................................................................... 1.42” .................................................. 36 mm
Stroke ............................................................................................ 1.65” .................................................. 42 mm
Crankcase Oil Capacity ................................................................ 118 .oz. ................................................ 3.5 L
Temperature of Pumped Fluids @ 1000 RPM ............................... 140 o F ................................................. 60 oC
Temperature of Pumped Fluids @ 500 RPM ................................. 160 o F ..................................................70 oC
Inlet Port .................................................................................................................................... (3) x 1-1/2” BSP
Discharge Port ................................................................................................................................. (3) x 1” BSP
Crankshaft Mounting ......................................................................................................................... Either Side
Shaft Rotation .................................................................................................... Top of Pulley Towards Fluid End
Weight .......................................................................................... 119 lbs. ................................................ 54 kg
Crankshaft Diameter ................................................................................................................................ 35 mm
LP200 HORSEPOWER REQUIREMENTS
RPM GPM 1000 PSI 1500 PSI 2000 PSI 3000 PSI
500 9.6 6.6 9.9 13.2 19.9
640 12.2 8.4 12.6 16.8 25.2
750 14.3 9.9 14.8 19.7 29.6
805 15.4 10.6 15.9 21.2 31.9
865 16.5 11.4 17.1 22.8 34.1
920 17.6 12.1 18.2 24.3 36.4
1000 19.1 13.2 19.8 26.3 39.5
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.
LP121A HORSEPOWER REQUIREMENTS
RPM GPM 500 PSI 1000 PSI 1500 PSI 1740 PSI
500 16.3 5.6 11.2 16.9 19.6
640 20.8 7.2 14.4 21.5 25.0
750 24.4 8.4 16.8 25.2 29.3
805 26.2 9.0 18.1 27.1 31.4
865 28.1 9.7 19.4 29.1 33.7
920 29.9 10.3 20.6 30.9 35.9
1000 32.5 11.2 22.4 33.6 39.0
HORSEPOWER INFORMATION
We recommend that a 1.1 service factor be speci-
ed when selecting an electric motor as the power source. To compute specic pump horsepower
requirements, use the following formula:
HP = (GPM X PSI) / 1450
3
Exploded View - LP121A-5100, LP200-5100, and LP250-5100
Important! The stainless steel valve plugs (48) can seize when being screwed out of the casing. To release tension beforehand, strike the plugs 1-2 times with a steel hammer on the top before screwing them out. Coat threads with antiseize (e.g. Fel-Pro Nickel Anti-Seize 51119)
4
4
LP121A-5100, LP200-5100, and LP250-5100 Parts List
ITEM PART DESCRIPTION QTY
1 07759 Crankcase 1
2 13000 Oil ller Plug Assembly 1
3 05940 Cover Plate 1 3A 07223-0100 Spring Ring 2 3B 05051-0100 Hexagon Screw 2 4 06085 Crankcase Cover 1 5 07104 O-ring, Crankcase Cover 1 6 05943 Oil Sight Glass Assembly 1 8 06086 Oil Dipstick Assembly 1 9 01009 O-Ring, Dipstick Assembly 1 10 01010-0100 Cylinder Screw 4 11 01011-0400 Spring Ring 5 12 07109-0400 Plug, 1/2” BSP 1 13 06015 O-Ring 1 14 07111 Bearing Cover 2 15 07112 Radial Shaft Seal 2 16 07113 O-Ring 2 17 07114-0100 Hexagon Screw 8 20 07116 Taper Roller Bearing 2 20A 07117 Fitting Disc 1-3 20B 13001 Fitting Disc 1-3 21 05376 Shaft Protector 1 21A 05377 Shaft Guard Holder 1 22 13242 Crankshaft 1 23 13243 Fitting Key 1 24 13340 Connecting Rod Assembly 3 24A 13227 Hex Screw 3 24B 13278 Spring Washer 3 25 13341 Crosshead / Plunger Assembly 3 28 13232 Crosshead Pin 3 29A 07125 Centering Sleeve 3 29B 13220 Plunger Pipe (LP200) 3 29B 13022 Plunger Pipe (LP250) 3 29B 07130 Plunger Pipe (LP121A) 3 29C 07131-0100 Tension Screw 3 29D 07161A-0100 Steel Ring 3 30 07779 Drip Shield 3 31 07133 Radial Shaft Seal 3 35 13228-0100 Seal Sleeve (LP200) 3 35 13024-0100 Seal Sleeve (LP250) 3 35 07135-0100 Seal Sleeve (LP121A) 3
ITEM PART DESCRIPTION QTY
36 13228 Leakage Seal (LP200) 3 36 13360 Leakage Seal (LP250) 3 36 13291 Leakage Seal (LP121A) 3 37 07170-0100 Seal Case (LP200, LP250) 3 37 07139-0100 Seal Case (LP121A) 3 38 07140 O-Ring (LP200, LP250) 3 38 07140 O-Ring (LP121A only) 6 38A 12055 O-Ring (LP200, LP250) 3 39 13197-0100 Pressure Ring (LP200) 3 39 13026-0100 Pressure Ring (LP250) 3 39 07142-0100 Pressure Ring (LP121A) 3 40 13115 V-Sleeve (LP200) 6 40 13027 V-Sleeve (LP250) 6 40 07144 V-Sleeve (LP121A) 6 41 13198-0100 Support Ring (LP200) 3 41 13028-0100 Support Ring (LP250) 3 41 07146-0100 Support Ring (LP121A) 3 42 07173 Tension Spring (LP200, LP250) 3 42 07147 Tension Spring (LP121A) 3 43 13018-5000 Valve Casing 1 44A 07150 O-Ring 9 44B 06266 Support Ring for O-Ring 3 45 06078 Compression Spring 3 46A 07064-0100 Valve Seat 6 46B 07063-0100 Valve Plate 6 46C 07062-0100 Valve Spring 6 46D 07066 Spacer Pipe 6 48 06077-0100 Plug 3 49 07157 Stud Bolt 8 49A 07158 Hexagon Nut 8 49B 07159 Disc 8 50 07423-0100 Plug 1 50A 07755-0100 Steel Ring 1 52 13020 Disc for Crankshaft 1 53 04561 Hexagon Screw 1 54 13044-0100 Plug, 1” BSP* 2 55 13322-0100 Plug 1-1/2” BSP* 2
*BSP to NPT Adapters/Seals (sold separately) Inlet = 13375-0100 (Adapter) / 13374-0100 (Seal) Discharge = 13373-0100 (Adapter) / 13372-0100 (Seal)
LP121A-5100, LP200-5100, and LP250-5100 REPAIR KITS
Plunger Packing Kits
LP200-5100 - #9307
Item Part# Description Qty. 36 13228 Leakage Seal 3 38 07140 O-Ring 3 38A 12055 O-Ring 3 40 13115 V-Sleeve 6
LP121A-5100 - #09720
Item Part# Description Qty. 36 13291 Leakage Seal 3 38 07140 O-Ring 6 40 07144 V-Sleeve 6
LP250-5100 - #9308
Item Part# Description Qty. 36 13360 Grooved Ring 3 38 07140 O-Ring 3 38A 12055 O-Ring 3 40 13027 V-Sleeve 6
5
Valve Kit - #09196-0100
Item Part# Description Qty. 44A 07150 O-Ring 9 44B 06266 Support Ring 3 46A 07064-0100 Valve Seat 6 46B 07063-0100 Valve Plate 6 46C 07062-0100 Valve Spring 6
Oil Seal Kit - #09577
Item Part# Description Qty. 31 07133 Oil Seal Kit 3
Specications
LP250 HORSEPOWER REQUIREMENTS
RPM
GPM 1000 PSI 1500 PSI 2000 PSI 2200 PSI
500 13.0 9.0 13.5 18.0 19.8 640 16.6 11.5 17.3 23.1 25.4 750 19.5 13.5 20.3 27.1 29.8 805 20.9 14.5 21.8 29.0 31.9 865 22.5 15.6 23.4 31.2 34.3 920 23.9 16.6 24.9 33.2 36.5
1000 26.0 18.0 27.1 36.1 39.7
Model LP250-5100
U.S. Metric
Volume .................................................................................26.0 GPM ......................... 98.3 LPM
Discharge Pressure ................................................................... 2200 PSI ................................. 150 Bar
Inlet Pressure ............................................................................. -4.35 to 87 PSI ..........-0.3 to 6.0 Bar
Speed ............................................................................................................................1000 RPM
Plunger Diameter .................................................................1.26” ......................................32 mm
Stroke ...................................................................................1.65” .......................................42 mm
Crankcase Oil Capacity ............................................................. 118 .oz. ...................................... 3.5 L
Temperature of Pumped Fluids ................................................ 140 o F .........................................60 o C
Inlet Port ................................................................................................................. 3 x 1-1/2” BSP
Discharge Port ........................................................................................................................ 3 x 1” BSP
Crankshaft Mounting .............................................................................................................. Either Side
Shaft Rotation .....................................................................................Top of Pulley Towards Fluid End
Weight .................................................................................119 lbs. ........................................ 54 kg
Crankshaft Diameter.............................................................................................................35 mm
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.
HORSEPOWER INFORMATION
We recommend that a 1.1 service factor be
specied when selecting an electric motor as the power source. To compute specic
pump horsepower requirements, use the following formula:
HP = (GPM X PSI) / 1440
6
LP121A-5100, LP200-5100, and LP250-5100 - Repair Instructions
44A 44B 45
1. With a 30mm wrench, remove the 3 plugs (48).
46A 46B 46D
4. Loosen valve seats (46A) from spacer pipe (46D) by lightly hitting the valve plate (46B) with a plastic stick. Check sealing surface and replace worn parts. Reassemble with new O-rings (44A) and oil them before installing. Tighten up tension plugs (48) to 107 ft.-lbs. (145 NM).
2. Remove the compression spring (45), O-rings and support rings (44A & 44B).
3. Remove the complete valve assembly (46A-46D) with valve pullers.
5. Loosen the 8 nuts (49A) with a 19mm wrench. Tap the back of the manifold (43) with a rubber mallet to dislodge and slide off the studs (49).
6. Pull seal sleeves (35) out of guides in crankcase (1).
42 41 40 40 39 35 36
7. Remove the tension spring (42), support ring (41), v-sleeves (40), pressure ring (39), from the seal sleeve (35). Examine seals (36) carefully and replace if worn. Clean all parts.
7
LP121A-5100, LP200-5100, and LP250-5100 - Repair Instructions
38/38A
29B 29D 29C
8. Remove seal case (37) from valve casing (43) and inspect O-rings (38/38A).
9. Check plunger surface (29B). If plunger pipe is worn, loos­en tension screws (29C) and pull off plunger pipe to the front. Clean front surface of plunger (25) thoroughly. Apply a thin coat of Loctite to the tension screw threads (29C).
Note: Care must be taken that no glue gets between the plunger pipe (29B) and the centering sleeve (29A).
Add new copper ring (29D).
10. Place new plunger pipe (29B) carefully through the oiled seals and push seal sleeve (35) with plunger pipe into the crankcase guide. Note:
Make sure weep hole is facing down.
11. Tighten the tension screws (29C) to 310 in.­lbs. (35NM).The plunger pipe (29B) should not be strained by over tighten­ing of the tension screw (29C) or through damage to the front surface of the plunger; otherwise, it will probably break.
12. Place valve vasing (43) over studs and
push rmly until seated
against the crankcase (1). Tighten the hexagon nuts (49A) in a crosswise pattern (shown below) to 59 ft.-lbs. (80 NM)
6
412
8
7
3
5
8
LP121A-5100, LP200-5100, and LP250-5100 - Repair Instructions
To Dismantle Gear End
After removing valve casing (43) and plunger pipe (29B), drain oil. Remove crankcase cover (4) and bearing cover (14). Loosen connecting rod screws (24A) and push the front of the connecting rod (24) forward as far as possible into the crosshead guide.
IMPORTANT! Connecting rods (24) are marked for identication. Do not twist connecting rod
halves. Connecting rod is to be reinstalled in the same position on shaft journals.
Turning the crankshaft (22) slightly, hit it out carefully to the side with a rubber hammer.
IMPORTANT! Do not bend the connecting rod (24) shanks. Check crankshaft (22) and connecting rod (24) surfaces, radial shaft seals (15) and taper roller bearings (20).
To Reassemble
Using a soft tool, press in the outer bearing ring until the outer edge lines up with the outer edge of the bearing hole. Remove bearing cover (14) together with radial shaft seal (15) and o-ring (16). Fit crankshaft (22) through bearing hole on the opposite side. Press in outer bearing and tighten it inwards with the bearing cover, keeping the crankshaft in 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 maximum 0.15mm by placing tting discs (20A and 20B) under
the bearing cover.
IMPORTANT! After assembly has been completed, the crankshaft should turn easily with very little clearance. Tighten connecting rod screws (24A) to 22 ft.-lbs. (30 NM).
LP121A-5100, LP200-5100, and LP250-5100 Torque Specications
Pos. Item # Description Lubrication Info Torque Amount
1 07759 Crankcase Molycote Cu-Paste
6 05943 Oil Sight Glass Assembly Loctite 572 29 ft.-lbs. (40 Nm)
10 01010-0100 Cylinder Screw 221 in.-lbs. (25 Nm)
12 07109-0400 Plug 29 ft.-lbs. (40 Nm)
17 07114-0100 Hexagon Screw 221 in.-lbs. (25 Nm)
24A 13227 Hex Screw 22 ft.-lbs. (30 Nm)
29C 07131-0100 Tension Screw Loctite 243 26 ft.-lbs. (35 Nm)
29D 07161A-0100 Steel Ring Loctite 577
31 07133 Radial Shaft Seal Loctite 403
48 06077-0100 Plug Pro Pack 550 107 ft.-lbs. (145 Nm)
49A 07158 Hexagon Nut 59 ft.-lbs. (80 Nm)
Pump Mounting Selection Guide
Bushings 06496 - 35mm H Bushing
Pulley & Sheaves 07165 - 12.75” Cast Iron - 4 gr. - AB Section
Rails 07357 - Plated Steel Channel Rails
(L=11.75” x W=1.88” x H=3.00”)
9
Pump System Malfunction
Preventative Maintenance Check List & Recommended Spare Parts List
Check Daily Weekly 50 hrs
Every
500 hrs
Every
1500 hrs
Every
3000 hrs
Oil Level/Quality X
Oil Leaks X
Water Leaks X
Belts, Pulley X
Plumbing X
Recommended Spare Parts
Oil Change (1 Quart) p/n 01153 X X
Seal Spare Parts (1 kit/pump) (see page 5 for kit list)
X
Oil Seal Kit (1 kit/pump) (see page 5 for kit list)
X
Valve Spare Parts (1 kit/pump) (see page 5 for kit list)
X
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, Rell 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
Pressure Drop at Gun Restricted discharge plumbing Re-size discharge plumbing to
ow rate of pump
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
10
LP121A-5100, LP200-5100, and LP250-5100 Dimensions - mm (in)
11
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 are guaranteed for the life of the pump. Our other pump parts, used in portable pressure washers and in car wash applications, are warranted
for ve 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 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 modications made by the customer or third party.
6. The operation of pumps and or accessories exceeding the specications 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 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 Ave., Toledo, Ohio 43607 PHONE (419) 531-4600, FAX (419) 531-6836, www.giantpumps.com Copyright 2019 Giant Industries, Inc.
02/19 LP200_250_121A-5100.indd
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