Giant LP121A-0011 User manual

Contents:
Installation Instructions: page 2
Pump Specications: page 3
Exploded View: page 4
Parts List: page 5
Kits: page 6
Pump Mounting Selection Guide: page 6
Repair Instructions: page 7-9
Torque Specications: page 9
Trouble Shooting: page 10
Recommended Spare Parts List: page 10
Dimensions: page 11
Warranty Information: back page
Triplex Ceramic
Plunger Pump
Operating Instructions/
Repair and Service
Manual
Updated 02/20
Models
LP121A/LP121A-0011/
LP200/LP250/LP250W-MT

2
INSTALLATION INSTRUCTIONS
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 oc-
curring, 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 stand-
ing 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 cir-
cumstances be consulted with regard to the
resistance of the pump material. It is the re-
sponsibility of the equipment manufacturer
and/or operator to ensure that all pertinent
safety regulations are adhered to.
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 emp-
tied. 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, conden-
sate (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%.
NOTE: Contact Giant Industries for Service School Information. Phone: [phone]

3
Specications
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
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.
RPM GPM 1000 PSI 1500 PSI 2000 PSI 2900 PSI
500 9.5 6.6 9.9 13.2 19.1
640 12.2 8.4 12.7 16.9 24.5
750 14.3 9.9 14.8 19.8 28.7
805 15.3 10.6 15.9 21.2 30.8
865 16.4 11.4 17.1 22.8 33.1
920 17.5 12.1 18.2 24.3 35.2
1000 19.0 13.2 19.8 26.4 38.3
LP200 HORSEPOWER REQUIREMENTS
RPM GPM 500 PSI 1000 PSI 1500 PSI 1740 PSI
500 16.3 5.6 11.3 16.9 19.6
640 20.8 7.2 14.4 21.7 25.1
750 24.4 8.5 16.9 25.4 29.5
805 26.2 9.1 18.2 27.3 31.6
865 28.1 9.8 19.5 29.3 34.0
920 29.9 10.4 20.8 31.1 36.1
1000 32.5 11.3 22.6 33.9 39.3
LP121A HORSEPOWER REQUIREMENTS
Max.
Flow
Max.
Flow
Pressure Pressure Max.
Speed
Max.
Inlet
Pressure
Max.
Inlet
Pressure
Plunger
Diameter
Plunger
Diameter
Power
Req’d
Power
Req’d
Model GPM l/min PSI bar RPM PSI bar in mm BHP kW
LP200 19.0 72.1 2900 200 1000 90 6.2 1.10 28 38.3 28.6
LP250 26.0 98.3 2200 150 1000 90 6.2 1.26 32 39.7 29.6
LP250W-MT 26.0 98.3 2200 150 1000 90 6.2 1.26 32 39.7 29.6
LP121A 32.5 123.1 1740 120 1000 90 6.2 1.42 36 39.3 29.3
LP121A-0011 32.5 123.1 1740 120 1000 90 6.2 1.42 36 39.3 29.3
U.S. Metric
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
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

4
Exploded View - LP121A, LP121A-0011, LP200, LP250, and LP250W-MT

5
LP121A, LP121A-0011, LP200, LP250, and LP250W-MT 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 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 1
10 01010 Cylinder Screw 4
11 01011-0400 Spring Ring 5
12 07109 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 Hexagon Screw 8
20 07116 Taper Roller Bearing 2
20A 07117 Fitting Disc, 0.1 mm 1-3
20B 13001 Fitting Disc, 0.15 mm 1-3
20C 04091 Shim, 0.2 mm
(may not be present) 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, LP250W-MT) 3
29B 07130 Plunger Pipe (LP121A) 3
29C 13031 Tension Screw 3
29D 07755 Copper Ring 3
30 07779 Drip Shield 3
31 07133 Radial Shaft Seal 3
35 13196 Seal Sleeve (LP200) 3
35 13024 Seal Sleeve
(LP250, LP250W-MT) 3
35 07135 Seal Sleeve (LP121A) 3
36 13291 Leakage Seal (LP121A) 3
36 13228 Leakage Seal (LP200) 3
36 13360 Leakage Seal (LP250) 3
36 13025 Leakage Seal (LP250W-MT) 3
37 07170 Seal Case (except LP121A) 3
37 07139 Seal Case (LP121A only) 3
38 07140 O-Ring
(except LP121A/LP121A-0011) 3
ITEM PART DESCRIPTION QTY
38 07140 O-Ring (LP121A only) 6
38 07140-0001 O-Ring, Viton
(LP121A-0011 only) 6
38A 12055 O-Ring (except LP121A) 3
39 13197 Pressure Ring (LP200) 3
39 13026 Pressure Ring
(LP250, LP250W-MT) 3
39 07142 Pressure Ring (LP121A) 3
40 07144 V-Sleeve (LP121A) 6
40 07144-0010 V-Sleeve (LP121A-0011)
40 13115 V-Sleeve (LP200) 6
40 13027 V-Sleeve (LP250, LP250W-MT) 6
41 13198 Support Ring (LP200) 3
41 13028 Support Ring
(LP250, LP250W-MT) 3
41 07146 Support Ring (LP121A) 3
42 07173 Tension Spring
(except LP121A/LP121A-0011) 3
42 07147 Tension Spring
(LP121A/LP121A-0011 only) 3
43 13029 Valve Casing 1
44A 07150 O-Ring (except LP121A-0011) 9
44A 07150-0001 O-Ring, Viton
(LP121A-0011 only) 9
44B 06266 Support Ring for O-Ring 3
45 06078 Compression Spring 3
46 07060 Valve Assembly (46A-D) 6
46A 07064 Valve Seat 6
46B 07063 Valve Plate 6
46C 07062-0100 Valve Spring 6
46D 07066 Spacer Pipe 6
48 06077 Plug 3
49 07157 Stud Bolt 8
49A 07158 Hexagon Nut 8
49B 07159 Disc 8
50 07423 Plug 1
50A 07161 Copper Ring 1
52 13020 Disc for Crankshaft 1
53 06607 Hexagon Screw 1
54 13321 Plug, 1” BSP* 2
55 13322 Plug 1-1/2” BSP* 2
05930 Manifold Assembly
(43-48/50/50A/54/55)
05445 Gear End Assembly
(1-29A/30/31/49/29A-B/52/53)
03055 Plunger Conversion Kit, LP200
(29B-D/35-42)
03116 Plunger Conversion Kit, LP250
(29B-D/35-42)
03117 Plunger Conversion Kit, LP121A
(29B-D/35-42)
*BSP to NPT Adapters/Seals (sold separately)
Inlet = 13375 (Adapter) / 13374 (Seal)
Discharge = 13373 (Adapter) / 13372 (Seal)
5

6
LP121A, LP121A-0011, LP200, LP250 SERIES & LP250W-MT Repair Kits
LP250 Series - #09308
Item Part# Description Qty.
36 13360 Grooved Ring 3
38 07140 O-Ring 3
38A 12055 O-Ring 3
40 13027 V-Sleeve 6
LP250W-MT - #09308-MT
Item Part# Description Qty.
36 13025 Leakage Seal 3
38 07140 O-Ring 6
38A 12055 O-Ring 3
40 13027 V-Sleeve 6
Valve Kit - #09196
Item Part# Description Qty.
44A 07150 O-Ring 9
44B 06266 Support Ring 3
46A 07064 Valve Seat 3
46B 07063 Valve Plate 3
46C 07062-0100 Valve Spring 3
LP121A - #09720
Item Part# Description Qty.
36 13291 Leakage Seal 3
38 07140 O-Ring 6
40 07144 V-Sleeve 6
LP121A-0011 - #09720-0010
Item Part# Description Qty.
36 13291 Leakage Seal 3
38 07140-0001 O-Ring 6
40 07144-0010 V-Sleeve 6
LP200 - #09307
Item Part# Description Qty.
36 13228 Leakage Seal 3
38 07140 O-Ring 3
38A 12055 O-Ring 3
40 13115 V-Sleeve 6
Oil Seal Kit - #09577
Item Part# Description Qty.
31 07133 Oil Seal Kit 3
Plunger Packing Kits
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”)

7
LP121A, LP121A-0011, LP200, LP250, and LP250W-MT - Repair Instructions
1. With a 30mm wrench,
remove the 3 plugs (48).
2. Remove the compression
spring (45), O-rings and
support rings (44A & 44B).
3. Remove the complete
valve assembly (46A-46D)
with valve pullers.
44A 44B 45
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).
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 o󰀨
the studs (49).
46A 46B
6. Pull seal sleeves (35) out of
guides in crankcase (1).
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.
42 41 40 40 39 35 36
46D

8
38/38A
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, loos-
en tension screws (29C) and pull o󰀨 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).
29B 29D 29C
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 tighten-
ing 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)
4
1
2
3
6
8
7
5
LP121A, LP121A-0011, LP200, LP250, and LP250W-MT - Repair Instructions

9
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 310 in.-lbs. (35 NM).
LP121A, LP121A-0011, LP200, LP250, and LP250W-MT - Repair Instructions
LP121A, LP121A-0011, LP200, LP250, and LP250W-MT Torque Specications
Pos. Item # Description Lubrication Info Torque Amount
1 07759 Crankcase Molycote Cu-Paste
605943 Oil Sight Glass Loctite 572 29 ft.-lbs. (40 Nm)
10 01010 Cylinder Screw 221 in.-lbs. (25 Nm)
12 07109 Plug 29 ft.-lbs. (40 Nm)
17 07114 Hexagon Screw 221 in.-lbs. (25 Nm)
24 13340 Connecting Rod Assembly 22 ft.-lbs. (30 Nm)
29C 13031 Tension Screw Loctite 243 26 ft.-lbs. (35 Nm)
31 07133 Radial Shaft Seal Loctite 403
48 06077 Plug 107 ft.-lbs. (145 Nm)
49 07157 Stud Bolt Loctite 270
49A 07158 Hexagon Nut 59 ft.-lbs. (80 Nm)

10
Pump System Malfunction
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
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
Oil Change
(1 Gallon) p/n 01154
X X
Plunger Seal Kit
(1 kit/pump) See page 5
X
Valve Repair Kit
(2 kits/pump) See page 5
X
Preventative Maintenance Check List & Recommended Spare Parts List
Recommended Spare Parts

11
LP121A, LP121A-0011, LP200, LP250 & LP250W-MT Dimensions - mm (in)

GIANT INDUSTRIES, INC., 900 N. Westwood Ave., Toledo, Ohio 43607
PHONE [phone], FAX [phone], www.giantpumps.com
 Copyright 2020 Giant Industries, Inc.
02/20 LP121A_LP200_LP250_LP250W-MT.indd
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.