Giant LP250-5100HK User manual

Contents:
Installation Instructions: page 2
Specications: page3
Exploded View : page 4
Parts List/ Kits: page 5
Repair Instructions: page 6-8
TorqueSpecications: page8
Pump Mounting Selection Guide: page 8
Trouble Shooting: page 9
Recommended Spare Parts List: page 9
Dimensions: page 10
Warranty Information: back page
Triplex Ceramic
Plunger Pump
Operating Instructions/
Repair and Service
Manual
Model
LP250-5100HK Pump

2
INSTALLATION INSTRUCTIONS
4. Use of a dampener is necessary to minimize
pulsation at drive elements, plumbing, con-
nections, 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 designat-
ed by the arrows on the pump crankcase. Re-
verse rotation may be safely achieved by follow-
ing a few guidelines available upon request from
Giant Industries, Inc. Required horsepower for
system operation can be obtained from the chart
on page 3.
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 ow freely to the inlet of the
pump.
IMPORTANT OPERATING CONDITIONS
Failure to comply with any of these conditions invalidates the war ranty.
2. Pump operation must not exceed rated pres-
sure, volume, or RPM. A pressure relief device
must be installed in the discharge of the system.
3. Acids, alkalines, or abrasive uids 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
rst 50 hours of operation, then at regular inter-
vals 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 at 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
ow rate of the pump with no unnecessary re-
strictions that can cause cavitation. Teon tape
should be used to seal all joints. If pumps are
to be operated at temperatures in excess of 1400
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 ow rate to pre-
vent line pressure loss to the work area. It is es-
sential 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 care-
lessly and without regard to its potential hazard, it can cause serious injury.

3

U. S............................................... Metric
Volume .......................................................................................... 26.0 GPM .............................. 98.4 LPM
Discharge Pressure ................................................................................2200 PSI ..................................151.7 BAR
Inlet Pressure .........................................................................................90 PSI ...................................... 6.2 BAR
Speed ............................................................................................................................................. 1000 RPM
Plunger Diameter .......................................................................... 1.26” ............................................ 32mm
Stroke ............................................................................................. 1.65” ............................................. 42mm
Crankcase Oil Capacity.........................................................................100 .oz. .......................................... 2.95 L
Temperature of Pumped Fluids............................................................140 oF................................................. 60 oC
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 ........................................................................................... 110 lbs. ...........................................49.9 kg
Crankshaft Diameter ...................................................................... 1.38”............................................ 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% toler-
ance on pumps output due to variations in pul-
leys, 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
We recommend that a 1.15 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) / 1450

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


5


ITEMPART DESCRIPTION QTY
1 07759 Crankcase 1
2 13000 Oilller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 01010-0100 Cylinder Screw 4
11 01011-0400 Spring Ring 5
12 12137 Plug 1
13 07182 Gasket 1
14 07111 Bearing Cover 2
15 07112 Radial Shaft Seal 2
16 07113 O-Ring 2
17 07114-0100 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 13022 Plunger Pipe 3
29C 07131-0100 Tension Screw 3
29D 07161-0100 Steel Ring 3
ITEMPART DESCRIPTION QTY
30 07789 Flinger 3
31 07133 Oil Seal 3
35 13024-0100 Steel Valve 3
36 13025 Grooved Ring 3
37 07170-0100 Seal Case 3
38 07140 O-Ring 3
38A 12055 O-Ring 3
39 13026-0100 Pressure Ring 3
40 13027 V-Sleeve 3
40A 06857 V-Sleeve,HighTemp. 3
41 13028-0100 Support Ring 3
42 07173 Tension Spring 3
43 13018-5000 Valve Casing 1
44A 07150 O-Ring 9
44B 06266 Support Ring for O-Ring 3
45 06078 Compression Spring 3
46A 07064 ValveSeat 6
46A 07064-0100 ValveSeat 6
46B 07063-0100 Valve Plate 6
46C 07062 Valve Spring 6
46D 07066 Spacer Pipe 6
48 06077-0100 Plug 3
49 07157 Stud bolt 8
49A 07158 HexagonNut 8
49B 07159 Disc 8
50 07483-0100 Plug 1
50A 07755-0100 SteelRing 1
52 13020 Disc for Crankshaft 1
53 13021 Hexagon Screw 1
54 13321-0100 Plug 1” BSP 2
55 13322-0100 Plug 1-1/2” BSP 2
Plunger Packing Kit - #9308-HK
Item Part# Description Qty.
36 13360 Grooved Ring 3
38 07140 O-Ring 3
38A12055 O-Ring 3
40 13027 V-Sleeve 3
40A 06857 V-Sleeve,HighTemp. 3
Valve Kit - #09196-0100
Item Part# Description Qty.
44A 07150 O-Ring 6
44B 06266 Support Ring 3
46A 7064-0100 ValveSeat 3
46B 7063-0100 Valve Plate 3
46C 07062 Valve Spring 3

6
REPAIR INSTRUCTIONS
1. With a 30mm wrench,
remove the (3) plugs (48).
2. Remove the compression
spring(45)&o-rings(44A
& 44B).
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)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
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

7
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, 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rmly
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
REPAIR INSTRUCTIONS

8
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 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 bear-
ing 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 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 07131-0100 Tension Screw, Plunger 310 in.-lbs.
48 06077-0100 Plug, Discharge 107 ft.-lbs.
 49A 07158 HexagonNut,StudBolts 59ft.-lbs.

Pump Mounting Selection Guide
Bushings
-35mmHBushing
Pulley & Sheaves
-12.75”CastIron-4gr.-ABSection
Rails
-PlatedSteelChannelRails
(L=11.75”xW1.88”xH=3.00”)
REPAIR INSTRUCTIONS

PUMP SYSTEM MALFUNCTION
MALFUNCTION
The Pressure and/or
the Delivery Drops
Water in crankcase
Noisy Operation
Rough/Pulsating
Operation with Pres-
sure Drop
Pressure Drop at Gun
Excessive Leakage
High Crankcase Tem-
perature
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, Rell 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 ow 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
9
Check Daily Weekly 50 Hrs.
Every
500
Hours
Every
1500
Hours
Every
3000
Hours
Oil Level/Quality X
Oil Leaks X
Water Leaks X
Belts, Puelly 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

10
LP250-5100HK PUMP DIMENSIONS- MM (INCHES)


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
  
water applications.
2. One (1) year from the date of shipment for all other Giant industrial and consumer
pumps.
  
  
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

1. Defects caused by negligence or fault of the buyer or third party.
  
3. Use of repair parts other than those manufactured or authorized by Giant.
4. Improper use of the product as a component part.
  
  
in the Operations Manuals provided by Giant Industries, Inc.

products returned freight prepaid to Giant Industries which are deemed to be defective due to work

warranty evaluation form is required prior to the return to Giant Industries of all products under war






       


02/07LP250-5100HK.PMD
,900N.WestwoodAve.,P.O.Box3187,Toledo,Ohio43607
PHONE(419)531-4600,FAX(419)531-6836,www.giantpumps.com
 Copyright2007GiantIndustries,Inc.