Triplex Ceramic
Plunger Pump
OperatingInstructions/
Repair and Service
Manual
Model
LP121HT
Contents:
InstallationInstructions: page 2
Pump Specifications:
Exploded View:
Parts List / Kits:
page 3
page 4
page 5
TorqueSpecifications: page 5
OperatingInstructions:
RepairInstructions:
Dimensions:
page 6
pages 7
back page
back page
WarrantyInformation:
Updated3/98
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Specifications
LP121HT Pump
Volume ........................................................................................................ Up to 17.6 GPM
Discharge Pressure .................................................................................... Up to 1200 PSI
Inlet Pressure.............................................................................................. Up to 90 PSI
Speed .......................................................................................................... Up to 570 RPM
Plunger Diameter........................................................................................ 36 mm
Stroke.......................................................................................................... 40 mm
Crankcase Oil Capacity .............................................................................. 116 fl.oz.
Temperature of Pumped Fluids................................................................... Up to 221 oF
Inlet Port ..................................................................................................... 1" BSP
Discharge Port............................................................................................ 1-1/4" BSP
Crankshaft Mounting .................................................................................. Either Side
Shaft Rotation ................................................................................ Top of Pulley Towards Fluid End
Weight......................................................................................................... 110 lbs.
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
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 PSI)/1450 = HP
LP121HT PULLEY SELECTION AND HORSEPOWER
REQUIREMENTS
RPM
200
300
400
500
570
GPM
6.2
9.3
12.4
15.5
17.6
300 PSI
600 PSI 900 PSI 1200 PSI
1.3
1.9
2.6
3.2
2.6
3.8
5.1
6.4
7.3
3.8
5.8
7.7
9.6
11.0
5.1
7.7
10.2
12.8
14.6
3.7
3
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EXPLODED VIEW - LP122A-3100
4
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PARTS LIST - LP122A-3100 PUMP
Item
1
2
4
5
6
8
9
10
11
12
13
14
15
16
17
20
20A
20B
21
22
23
24
25
28
29A
29B
Part
Description
Crankcase
Qty.
1
1
1
1
1
1
1
4
5
1
1
2
2
2
8
2
Item
30
31
Part
07779
07133
Description
OilScraper
RadialShaftSeal
Qty.
3
3
3
3
3
3
3
6
3
3
3
1
6
6
6
6
6
6
6
8
8
8
1
1
1
1
1
1
07759
13000
06085
07104
07186
06086
01009
08093
08094
12137
07182
07111
07112
07113
08095
07116
07117
13001
07118
13242
13243
13340
13341
13232
07735
07736
OilFillerPlugAssy
CrankcaseCover
O-Ringfor4
OilSightGlassAssey
OilDipstickAssey
O-Ringfor8
CylinderScrew
SpringRing
PlugG1/2
35 13342-0200 SealSleeve
35A
36
06619
13415
O-Ring
GroovedRing
36A 13416-0200 PressureRing
39 07744-0100 PressureRing
40
41 06621-0100 SupportRing
42 06589 PlugG1/8
42A 07258-0100 SteelRing
43 13018-3000 ValveCasing
44 07748-0300 ValveSeat
07745
V-Sleeve
Gasket
BearingCover
RadialShaftSeal
O-Ringfor14
HexagonScrew
TaperRollerBearing
FittingDisc
FittingDisc
ShaftProtector
Crankshaft
FittingKey
ConectingRodAssey
Crosshead/PlungerAssy 3
CrossheadPin
CenteringSleeve
PlungerPipe
44A
06620
O-Ring
45 07749-0300 ValvePlate
46
47
48
48A
49
49A
49B
50 07423-0100 ????????
50A 07755-0100 SteelRing
52
53
54 13321-0100 PlugG1
55 13322-0100 PlugG11/2
07750
07752
06089
06577
07157
07158
07159
ValveSpring
SpringTensionCap
Plug
1-3
1-3
1
1
1
O-Ring
StudBolt
HexagonNut
Disc
3
3
3
3
3
3
3
13020
13021
DiscforCrankshaft
HexagonScrew
29C 07737-0100 TensioningScrew
29D 07161-0100 SteelPipe
29E
06618
SpacerPipe
LP122A-3100 PUMP REPAIR KITS
LP122A-3100 PUMP TORQUE SPECIFICATIONS
Position
Item#
Description
Torque Amount
5
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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.-lbs.
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.-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.-lbs.
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 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.-lbs.
NOTE: Contact Giant Industries for Service School Information. Phone: (419)-531-4600
6
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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 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.
7
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LP121HT DIMENSIONS, INCHES (MM)
GIANTINDUSTRIESLIMITEDWARRANTY
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
willneverfail,period.Iftheyeverfail,wewillreplacethemfreeofcharge.Ourotherpump
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 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,EXPRESSORIMPLIED,INCLUDINGWITHOUTLIMITATIONANYWARRAN-
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 43607
Ó Copyright 1998 Giant Industries, Inc.
3/98 LP121HT.PM5
8
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