Giant LP200-SS User manual

Contents:
Installation Instructions: page 2
LP200-SS Specications: page 3
Exploded View / Kits: page 4
Parts List/Kits: page 5
Repair Instructions: pages 6-9
Torque Specications: page 9
Pump Mounting Selection Guide: page 9
Trouble Shooting: page 10
Maintenance/Spare Parts List: page 10
Dimensions: page 11
Warranty Information: back page
Triplex Ceramic
Plunger Pump
Operating Instructions/
Repair and Service Manual
Model
LP200-SS
Updated 01/20

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
U.S Metric
Volume .......................................................................................... 19.0 GPM ..................................... 72.1 LPM
Discharge Pressure ...................................................................... 3000 PSI ......................................... 200 Bar
Inlet Pressure ............................................................................... -4.35 to 90 PSI ...................... -0.3 to 6.2 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 o C
Temperature of Pumped Fluids @ 500 RPM................................. 160 o F ................................................. 70 o C
Inlet Port .................................................................................................................................... (3) x 1-1/4” 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
Manifold Material ....................................................................................................................303 Stainless Steel
Model LP200-SS 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

4
Exploded View - LP200-SS

5
LP200-SS Parts List
LP200-SS Pump Repair Kits
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 1
8 06086 Oil Dipstick Assembly 1
9 01009 O-Ring, Dipstick Assembly 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 3
29C 13031 Tension Screw 3
29D 07755 Copper Ring 3
ITEM PART DESCRIPTION QTY
30 07779 Drip Shield 3
31 07133 Radial Shaft Seal 3
35 13196 Seal Sleeve 3
36 13228 Leakage Seal 3
37 07170 Seal Case 3
38 07140 O-Ring 3
38A 12055 O-Ring 3
39 13197 Pressure Ring 3
40 13115 V-Sleeve 6
41 13198 Support Ring 3
42 07173 Tension Spring 3
43 13040 Valve Casing 1
44A 07150 O-Ring 9
44B 06266 Support Ring for O-Ring 3
45 06078 Compression Spring 3
46 07060 Valve Assy, Complete 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 12250 Plug 1/2” BSP 1
50A 07661 Copper Seal 1
52 13020 Disc for Crankshaft 1
53 04561 Hexagon Screw 1
54 13044 Plug, 1” BSP 1
55 13151 Plug 1-1/4” BSP 1
03055 Plunger Conversion Assembly
(29B-D, 35-42)
Plunger Packing Kits - #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
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
Oil Seal Kit - #09577
Item Part# Description Qty.
31 07133 Oil Seal Kit 3
*BSP to NPT Adapters/Seals (sold separately)
Inlet Port = 13377 (Adapter) / 13376 (Seal)
Discharge Port = 13373+ (Adapter) / 13372 (Seal)

6
1) Loosen and remove
tension plugs (48) with a
36mm socket wrench.
TO CHECK VALVES
NOTE: Always take time to lubricate all metal and non-metal parts with a light lm of oil before reassembling. This step
will help ensure proper t, at the same time protecting the pump non-metal parts (elastomers) from cutting and scoring.
44B 44A 45
2) Remove the support ring
(44B), O-ring (44A) and
tension spring (45).
3) Take out discharge valve
assemblies (46) by pull-
ing them upwards out of
the valve casing (43) with
a snap-ring tongs or any
other pull-o󰀨 device. Then
remove inlet valves in the
same way.
4) Loosen valve seats (46A)
and valve spring (46C)
from spacer pipe (46D)
by lightly hitting the valve
plate (46B) with a plastic
stick. LP600/LP600-4000
pumps have an addi-
tional valve spring guide
(46E). Check sealing
surface and replace worn
parts. Reassemble with
new O-rings (44A) if pos-
sible and oil them before
installing.
5) Tighten up tension plugs
(48) to 59 ft.-lbs. (80
Nm).
46A
46D
46B
46C
LP200-SS Repair Instructions

7
8) 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.
9) Remove seal case (37)
from valve casing (43)
and inspect O-rings
(38/38A).
10) Check plunger surface (29B). If plunger pipe is
worn, loosen 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).
11) 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.
6) Loosen the 8 nuts (49A)
with a 19mm socket and
pull o󰀨 valve casing (43)
to the front.
LP200-SS Repair Instructions
TO CHECK SEALS
7) Pull seal sleeves (35) out
of guides in crankcase (1).

8
12) Tighten the tension screws
(29C) to 310 in.-lbs. (35NM).
The plunger pipe (29B) should
not be strained by over tight-
ening of the tension screw
(29C) or through damage to
the front surface of the plung-
er; otherwise, it will probably
break.
13) Place entire manifold/seal
sleeve assembly over the
studs and push firmly until
seated against the crank-
case.
LP200-SS Repair Instructions
14) Tighten hex nuts (49A) in a
crosswise pattern (shown
above) to 59 ft.-lbs. (80
Nm).
LP200-SS Torque Specications
Position 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, 1/2” BSP 29 ft.-lbs. (40 Nm)
17 07114 Hexagon Screw 221 in.-lbs. (25 Nm)
24 13340 Inner Hex Screw, Connecting Rod 22 ft..-lbs. (30 Nm)
29C 13031 Tension Screw, Plunger Loctite 243 26 ft.-lbs. (35 Nm)
29D 07161A-0100 Seal Sleeve Loctite 577
31 07133 Radial Shaft Seal Loctite 403
48 06077 Plug, Discharge 107 ft.-lbs. (145 Nm)
49 07157 Stud Bolt Loctite 270
49A 07158 Hexagon Nut, Stud Bolts 59 ft.-lbs (80 Nm)

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 crank-
shaft (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 roll-
ers 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).
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”)
LP 200-SS - Repair Instructions

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
Pump Dimensions - Inches(mm)

GIANT INDUSTRIES, INC., 900 N. Westwood Ave., Toledo, Ohio 43607
PHONE [phone], FAX [phone], www.giantpumps.com
 Copyright 2020 Giant Industries, Inc.
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 mani
folds 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 applica
tions, 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 manufac-
turer’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 war-
ranty consideration. Call (419)-531-4600 or fax [phone] 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 WARRAN-
TIES OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE AND ALL SUCH
WARRANTIES ARE HEREBY DISCLAIMED AND EXCLUDED BY THE MANUFACTURER.
02/20 LP200-SS.indd