Giant LP200 User manual

Model
LP200, LP250 & LP250W-MT
Triplex Ceramic
Plunger Pump
Operating Instructions/
Repair and Service
Manual
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 7-9
Torque Specifications: page 9
Pump Mounting Selection
Guide: page9
Trouble Shooting: page 10
Recommended
Spare Parts List: page 10
Dimensions: page 11
Warranty Information: back page

2
INSTALLATION INSTRUCTIONS
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.
IMPORTANT OPERATING CONDITIONS
Failure to comply with any of these conditions invalidates the warranty.
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.
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.
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
1400F, 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 line 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.
Finally, remember that high pressure operation in a pump system has many advantages. But, if it is used carelessly
and without regard to its potential hazard, it can cause serious injury.

3
Volume ........................................................................................................ Up to19.0 GPM
Discharge Pressure .................................................................................... Up to 2900 PSI
Inlet Pressure.............................................................................................. Up to 90 PSI
Speed .......................................................................................................... Up to 1000 RPM
Plunger Diameter ........................................................................................ 28 mm
Stroke .......................................................................................................... 42 mm
Crankcase Oil Capacity .............................................................................. 100 fl.oz.
Temperature of Pumped Fluids................................................................... Up to 140 oF
.................................................................................................................... 1600F up to 500 RPM
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 ......................................................................................................... 116 lbs.
Crankshaft Diameter .................................................................................. 35 mm
Specifications
Model LP200
*Intermittent duty for pump speeds in excess of 805 RPM
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
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 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.
LP200 HORSEPOWER REQUIREMENTS
RPM GPM 1000 PSI 1500 PSI 2000 PSI 2900 PSI
500 9.5 6.6 9.9 13.2 19.2
640 12.2 8.5 12.7 16.9 24.6
750 14.3 9.9 14.9 19.8 28.8
805 15.3 10.6 16.0 21.3 30.9
865
16.5 11.4 17.2 22.9 33.2
920
17.5 12.2 18.3 24.3 35.3
1000 19.0 13.2 19.8 26.5 38.4

4
Exploded View - LP200, LP250 & LP250W-MT

5
LP200, LP250 & LP250W-MT PARTS LIST
LP200, LP250 & LP250W-MT REPAIR KITS
ITEM PART DESCRIPTION QTY
1 07759 Crankcase 1
2 13000 Oil filler Plug Assy. 1
4 06085 Crankcase Cover 1
5 07104 O-ring, Crankcase Cover 1
6 07186 Oil Sight Glass 1
7 07187 Gasket for Sight Glass 1
8 06086 Oil Dipstick Assy 1
9 01009 O-Ring, Dipstick Assy. 1
10 01010 Cylinder Screw 4
11 01011 Spring Ring 5
12 07109 Plug 1
13 07182 Gasket 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 1-3
20B 13001 Fitting Disc 1-3
21 07118 Shaft Protector 1
22 13242 Crankshaft 1
23 13243 Woodruff Key 1
24 13340 Connecting Rod Assy. 3
24A 13227 Hex Screw 3
24B 13278 Spring Washer 3
25 13341 Crosshead / Plunger Assy. 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
29C 07131 Tension Screw 3
29D 07755 Copper Ring 3
30 07789 Flinger 3
31 07133 Oil Seal 3
35 13196 Seal Sleeve (LP200) 3
35 13024 Seal Sleeve
(LP250, LP250W-MT) 3
36 13228 Leakage Seal (LP200) 3
ITEM PART DESCRIPTION QTY
36 13360 Grooved Ring (LP250) 3
36 13025 Leakage Seal (LP250W-MT) 3
37 07170 Seal Case 3
38 07140 O-Ring 3
38A 12055 O-Ring 3
39 13197 Pressure Ring (LP200) 3
39 13026 Pressure Ring
(LP250, LP250W-MT) 3
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 06702 Sleeve Support (LP255) 3
42 07173 Tension Spring 3
43 13029 Valve Casing 1
44A 07150 O-Ring 9
44B 06266 Support Ring for O-Ring
(LP250W-MT only) 3
45 06078 Compression Spring
(LP250W-MT) 3
46 07060 Valve Assembly 6
46A 07064 Valve Seat 6
46B 07063 Valve Plate 6
46C 07062 Valve Spring 6
46D 07066 Spacer Pipe 6
48 07156 Plug 3
48 06077 Plug (LP250W-MT) 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 13021 Hexagon Screw 1
54 13321 Plug, 1 BSP 1
55 13322 Plug 1-1/2 BSP 1
Plunger Packing Kits
LP200 # 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
LP250, LP250W # 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
LP250W-MT # 9308-MT
Item Part # Description Qty.
36 13025 Leakage Seal 3
38 07140 O-Ring 3
38A 12055 O-Ring 3
40 13027 V-Sleeve 6
Valve Kit
# 09196
Item Part # Description Qty.
46A 07064 Valve Seat 1
46B 07063 Valve Plate 1
46C 07062 Valve Spring 1

6
Specifications
Model LP250, LP250W-MT
Volume ........................................................................................................ Up to 26.0 GPM
Discharge Pressure .................................................................................... Up to 2200 PSI
Inlet Pressure.............................................................................................. Up to 90 PSI
Speed .......................................................................................................... Up to 1000 RPM
Plunger Diameter ........................................................................................ 32 mm
Stroke .......................................................................................................... 42 mm
Crankcase Oil Capacity .............................................................................. 100 fl.oz.
Temperature of Pumped Fluids................................................................... Up to 140 oF
Inlet Port ..................................................................................................... 1-1/24" BSP
Discharge Port ............................................................................................ 3 x 1" BSP
Crankshaft Mounting .................................................................................. Either Side
Shaft Rotation ................................................................................ Top of Pulley Towards Fluid End
Weight ......................................................................................................... 110 lbs.
Crankshaft Diameter .................................................................................. 35 mm
*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 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
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 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

7
LP200, LP250 & LP250W-MT - REPAIR INSTRUCTIONS
1. With a 30mm wrench,
remove the (3) plugs (48).
2. Remove the compression
spring (45) & o-rings (44A
& 44B-LP250W-MT only).
3. Remove the complete valve
assembly (46) 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) if possible and oil them before installing. Tighten up
tension plugs (48) to 107 ft.-lbs.
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).
46A 46B 46D
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

8
38
8. Remove seal case (37) from
valve casing (43) and inspect
o-ring (38).
9. 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).
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. 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.
4
1
2
3
6
8
7
5
LP200, LP250 & LP250W-MT - REPAIR INSTRUCTIONS

9
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 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 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.-lbs.
Position Item# Description Torque Amount
24 13340 Inner Hex Screw, Connecting Rod 310 in.-lbs.
29C 07131 Tension Screw, Plunger 310 in.-lbs.
48 07156 Plug, Discharge 107 ft.-lbs.
49A 07158 Hexagon Nut, Stud Bolts 59 ft.-lbs.
LP200, LP250 & LP250W-MT TORQUE SPECIFICATIONS
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xW1.88xH=3.00)

10
PUMP SYSTEM MALFUNCTION
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
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 humidity
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 with recommended 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 plumbing to flow rate
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 & Recommended Spare Parts List
Check Daily Weekly 50hrs Every Every Every
500 hrs 1500 hrs 3000 hrs
Oil Level/Quality X
Oil Leaks X
Water Leaks X
Belts, Pulley X
Plumbing X
Recommended Spare Parts
Oil Change (1 Gallon) p/n 1154 X X
Oil Seal Kit (1 kit/pump) X
(See page 5 for kit lit)
Valve Spare Parts (1 kit/pump) X
(See page 5 for kit list)

11
LP200, LP250 & LP250W-MT DIMENSIONS

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.
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 [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.
5/02LP200_250_250W_MT.PM6
GIANT INDUSTRIES, INC., 900 N. Westwood Ave., P.O. Box 3187, Toledo, Ohio 43607
PHONE [phone], FAX [phone], www.giantpumps.com
Ó Copyright 2002 Giant Industries, Inc.