Giant LP200 User's Manual
Contents
1. 11 Tighten the tension screws 29C to 310 in lbs 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 firmly until seated against the crankcase 1 Tighten the hexagon nuts 49A in a crosswise pattern shown below to 59 ft lbs AE E e Da Best Z E Ll To Dismantle Gear End After removing valve casing 43 and plunger pipe 29B drain oil Remove gear 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 identification 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 b2. Model Home Triplex Ceramic Plunger Pump Operating Instructions Repair and Service Manual LP200 LP250 amp LP250W MT Updated 5 02 Contents Installation Instructions page 2 LP200 Specifications page 3 Exploded View Kits page 4 Parts List page 5 LP250 LP250W MT Specifications page 6 Repair Instructions page 9 Torque Specifications page 9 Pump Mounting Selection Guide Dade9 Trouble Shooting page 10 Recommended Spare Parts List 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 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 140 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 l
3. spring 45 amp o rings 44A assembly 46 with valve amp 44B LP250W MT only pullers 4 Loosen valve seats 46A from spacer pipe 46D by lightly 5 Loosen the 8 nuts 49A hitting the valve plate 46B with a plastic stick Check sealing with a 19mm wrench Tap surface and replace worn parts Reassemble with new o rings the back of the manifold 44A if possible and oil them before installing Tighten up 43 with a rubber mallet tension plugs 48 to 107 ft lbs to dislodge and slide off the studs 49 6 Pull seal sleeves 35 out of 7 Remove the tension spring 42 support ring 41 v sleeves 40 guides in crankcase 1 pressure ring 39 from the seal sleeve 35 Examine seals 36 carefully and replace if worn Clean all parts LP200 LP250 amp LP250W MT REPAIR INSTRUCTIONS 8 Remove seal case 37 from valve casing 43 and inspect o ring 38 Check plunger surface 29B If plunger pipe is worn out 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
4. 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 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 Giant gear lube oil p n 1154 or the equivalent 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 Model LP200 Ke Discharge PresSUre eege Inlel PreSSUNE SGC Dd Crankcase Oil Capacity ii Temperature of Pumped Fluids i Discharge PO oo Crankshaft Mounting E SAL RO We ecc Crankshaft Diameter i ei Up to19 0 GPM EE Up to 2900 PSI EE Up to 90 PSI Pe re eer rer ere Up to 1000 RPM SE 28 mm EEN Up to 140 F SEENEN 160 F up to 500 RPM EE 3 x 1 1 2 BSP E 3 x 1 BSP E Either Side ee ee Top of Pulley Towards Fluid End S
5. E 116 lbs Intermittent duty for pump speeds in excess of 805 RPM 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 toler ance on pumps output due to variations in pulleys belts and motors among manufactur ers 1 Select GPMrequired 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 specified when selecting an electric motor as the power source To compute specific pump horsepower requirements use the following formula HP GPM X PSI 1440 LP200 HORSEPOWER REQUIREMENTS RPM GPM 1000 PSI 1500 PSI 2000 PSI 500 9 5 6 6 9 9 13 2 19 2 640 12 2 8 5 12 7 16 9 24 6 790 14 3 9 9 14 9 805 15 3 865 16 5 1000 19 0 920 17 5 12 2 18 3 Exploded View LP200 LP250 amp LP250W MT ITEM PART 1 07759 2 13000 4 06085 5 07104 6 07186 7 07187 8 06086 H 01009 10 01010 11 01011 12 07109 13 07182 14 07111 15 07112 16 07113 17 07114 20 07116 20A 07117 20B 13001 21 07118 22 13242 23 13243 24 13340 24A 13227 24B 13278 25 13341 28 13232 29A 07125 29B 13220 29B 13022 29C 07131 29D 07755 30 07789 31 07133 35 13196 35 13024 36 13228 LP200 LP250 amp LP250W MT PARTS LIST DESCRIPTIO
6. LP255 Tension Spring Valve Casing O Ring Support Ring for O Ring LP250W MT only Compression Spring LP250W MT Valve Assembly Valve Seat Valve Plate Valve Spring Spacer Pipe Plug Plug LP250W MT Stud bolt Hexagon Nut Disc Plug Copper Ring Disc for Crankshaft Hexagon Screw Plug 1 BSP Plug 1 1 2 BSP LP200 LP250 amp LP250W MT REPAIR KITS Plunger Packing Kits LP200 Item Part 36 13228 38 07140 38A 12055 40 13115 LP250 LP250W Description Leakage Seal 3 O Ring 3 O Ring 3 V Sleeve 6 9307 Item Part 36 13360 38 07140 38A 12055 40 13027 Description Grooved Ring 3 O Ring 3 O Ring 3 V Sleeve 6 LP250W MT Item Part 36 13025 38 07140 38A 12055 40 13027 Valve Kit 09196 Part 07064 07063 07062 Item 46A 46B 46C Description Leakage Seal O Ring O Ring V Sleeve Description Valve Seat Valve Plate Valve Spring 9308 MT ON WwW W WwW Qty 1 1 1 k bah k k bah k OO OO O Lu Lal ON Oh Ch Oh Ch w Lal iO bech WW Lal CO OV OV Ww K Specifications Model LP250 LP250W MT MW roii pe E E ene oe Discharge Pres tie ee Iiet 1 10 De Plunger Diameter i ter Crankcase Oil Capacity i Temperature of Pumped Fluids let POr ennn A A A Discharge MORERRERETTITTIVIKAKWAWAKKvY YY ho Crankshaft Mounting i Shan Rotali ol oe ai
7. N Crankcase Oil filler Plug Assy Crankcase Cover O ring Crankcase Cover Oil Sight Glass Gasket for Sight Glass Oil Dipstick Assy O Ring Dipstick Assy Cylinder Screw Spring Ring Plug Gasket Bearing Cover Radial Shaft Seal O Ring Hexagon Screw Taper Roller Bearing Fitting Disc Fitting Disc Shaft Protector Crankshaft Woodruff Key Connecting Rod Assy Hex Screw Spring Washer Crosshead Plunger Assy Crosshead Pin Centering Sleeve Plunger Pipe LP200 Plunger Pipe LP250 LP250W MT Tension Screw Copper Ring Flinger Oil Seal Seal Sleeve LP200 Seal Sleeve LP250 LP250W MT Leakage Seal LP200 QTY WwW CONN N bh bh WSs bei Fe be bech bel bel kel Fe ke ke kl bs 4 Ww U Lal WW LU WW UW WW Lal LU UW WwW LW La ITEM 36 36 37 38 38A 39 39 A0 A0 Al Al Al 42 43 44A 44B 45 46 46A 46B 46C 46D 48 48 49 49A 49B 50 50A 32 53 54 53 PART 13360 13025 07170 07140 12055 13197 13026 13115 13027 13198 13028 06702 07173 13029 07150 06266 06078 07060 07064 07063 07062 07066 07156 06077 07157 07158 07159 07423 07161 13020 13021 13321 13322 DESCRIPTION Grooved Ring LP250 Leakage Seal LP250W MT Seal Case O Ring O Ring Pressure Ring LP200 Pressure Ring LP250 LP250W MT V Sleeve LP200 V Sleeve LP250 LP250W MT Support Ring LP200 Support Ring LP250 LP250W MT Sleeve Support
8. e a ENEE DEE Crankshaft Diameter i EES Up to 26 0 GPM SE Up to 2200 PSI SE Up to 90 PSI EE Up to 1000 RPM Ee 32 mm EE Up to 140 F ee 1 1 24 BSP Ee 3 x 1 BSP EE Either Side EE Top of Pulley Towards Fluid End SEENEN 110 Ibs Intermittent duty for pump speedsin excess of 805 RPM 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 toler ance on pumps output due to variations in pulleys belts and motors among manufactur ers 1 Select GPMrequired 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 specified when selecting an electric motor as the power source To compute specific pump horsepower requirements use the following formula HP GPM X PSI 1440 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 20 4 790 19 5 13 5 20 3 805 20 9 14 5 865 22 5 15 6 920 23 9 16 6 24 9 1000 26 0 18 0 27 1 27 1 29 8 29 0 31 9 31 2 34 3 33 2 36 5 36 1 39 7 LP200 LP250 amp LP250W MT REPAIR INSTRUCTIONS 1 With a 30mm wrench 2 Remove the compression 3 Remove the complete valve remove the 3 plugs 48
9. earing 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 fitting discs 20A and 20B under the bearing cover IMPORTANT After assembly has been completed the crankshaft should turn easily with very little clear ance Tighten connecting rod screws 24A to 310 in Ibs LP200 LP250 amp LP250W MT TORQUE SPECIFICATIONS Position lItem Description Torque Amount 2A 13340 Inner Hex Screw Connecting Rod 310 in lbs 29C 07131 Tension Screw Plunger 310 in lbs 48 07156 Plug Discharge 107 ft Ibs 49A 07158 Hexagon Nut Stud Bolts 59 ft Ibs 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 XW1 88 KH 3 00 MALFUNCTION The Pressure and or the Delivery Drops Water in crankcase Noisy Operation Rough Pulsating Operation with Pressure Drop Pressure Drop at Gun Excessive Leakage High Crankcase Temperature PUMP SYSTEM MALFUNCTION 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 Unloader High hum
10. ee page 5 for kit list Daily Weekly SOhrs Every S00 hrs 10 Every Every 1500 hrs 3000 hrs LP200 LP2S0 amp LP250W MT DIMENSIONS Fitting Key 60 10x 8x 50 A lt col TI 1 sl TE Centering Hole OS M8 DN 332 Discharge 3x 1 BSP 51 Inlet 3x 11 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 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 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 Normal wear and tear to standard wear parts Use of repair par
11. hio 43607 PHONE 419 531 4600 FAX 419 531 6836 www qiantpumps com Copyright 2002 Giant Industries Inc 5 02LP200_250_250W_MT PM6
12. idity Worn seals Worn bearings 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 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 pump for restrictions Check for proper operation Reduce oil change interval Replace seals Replace bearings Refill crankcase oil withrecommended 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 for restrictions and or proper size Re size discharge plumbingto flowrate 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 Oil Level Quality Oil Leaks Water Leaks Belts Pulley Plumbing Oil Change 1 Gallon p n 1154 Oil Seal Kit 1 kit pump See page 5 for kit lit Valve Spare Parts 1 kit pump S
13. ine 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 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 obtained from the charts on pages 3 and 6 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
14. ts 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 Dn e 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 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 LIMITATIONANY 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 Ave P O Box 3187 Toledo O
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