Giant LP301A-0081 User manual

Contents:
Installation Instructions: page 2
Specications: page3
Exploded View: page 4
Parts List/Repair Kits: page 5
Repair Instructions: page 6-9
TorqueSpecications: page9
Pump Mounting Selection Guide: page 9
Trouble Shooting/Preventative
Maintenance Check-List
& Recommended Spare Parts List: page 10
Dimensions: page 11
Warranty Information: back page
Triplex Ceramic
Plunger Pump
Operating Instructions/
Manual
Model
LP301A-0081
Teon/Nitrile Seals with
Viton O-Rings

2
INSTALLATION INSTRUCTIONS
4. Use of a dampener is necessary to mini-
mize pulsation at drive elements, plumbing,
connections, 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
pulsation. Dampeners can also reduce the
severity of pressure spikes that occur in sys-
tems 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 ob-
tained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. Cavi-
tation 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 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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
crankcase so that oil level is between the
two lines on the oil dipstick. DO NOT
OVERFILL.
Use SAE 85W-90 industrial gear lube oil
(Giant’s p/n 01154)
Crankcase oil should be changed after
therst50hoursofoperation,thenatregu-
lar 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 instal-
lation. 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unneces-
sary restrictions 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 1400F, it is important to insure
a positive head to the pump to prevent cavita-
tion.
3.Thedischargeplumbingfromthepump
shouldbeproperlysizedtotheow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.
NOTE: Contact Giant Industries for Service School Information. Phone: [phone]

3
Model LP301A-0081 Specications
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 mo-
tors 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
U.S. Metric
Flow..........................................................14.2 GPM ..........................................53.6LPM
Pressure ...................................................4000 PSI............................................... 275 bar
Speed .......................................................1000 RPM ....................................... 1000 RPM
Inlet Pressure ...........................................-4.35to145PSI ......................... -0.3to10Bar
Plunger Diameter......................................0.95” ..................................................... 24 mm
Stroke .......................................................1.65” ..................................................... 42 mm
Crankcase Oil Capacity............................118.oz. ............................................ 3.5Liters
Temperature of Pumped Fluids ................140 oF ...................................................... 60 oC
Inlet Port ............................................................................................................1-1/4” BSP
Discharge Port.........................................................................................................1” BSP
Crankshaft Mounting .........................................................................................Either Side
Shaft Rotation.................................................................. Top of Pulley Towards Fluid End
Weight ......................................................119 lbs. .................................................... 54 kg
Crankshaft Diameter............................................................................................... 35mm
LP301A-0081 PULLEY SELECTION AND
HORSEPOWER REQUIREMENTS
RPM GPM 2500 PSI 3000 PSI 3500 PSI 4000 PSI
500 7.1 12.2 14.6 17.0 19.4
640 9.0 15.6 18.7 21.8 24.9
750 10.6 18.2 21.9 25.5 29.2
805 11.4 19.6 23.5 27.4 31.3
865 12.2 21.0 25.2 29.4 33.7
940 13.3 22.8 27.4 32.0 36.6
1000 14.2 24.5 29.4 34.3 39.2

4
Exploded View - LP301A-0081
Important! The stainless steel valve plugs (48) can seize when being screwed out of the cas-
ing. To release tension beforehand, strike the plugs 1-2 times with a steel hammer on the top
before screwing them out. Coat threads with antiseize (e.g. Fel-Pro Nickel Anti-Seize 51119)

5
ITEM PART DESCRIPTION QTY
36 13238 LeakageSeal 3
37 13240 SealCase 3
38 07140 O-Ring,SealCase 3
38A 13241 SupportRingfor38 3
39 12055-0001 O-Ring 3
39A 07693 SupportRingfor39 3
40 06083 V-Sleeve 3
40A 13366 PressureRing 3
40B 13367 GuideRingfor40 3
40C 06083A-0020 Sleeve,Teon 3
41 07338 PressureSpring 3
43 13040 ValveCasing 1
44A 07150-0001 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, G-1/2”, S.S. 1
50A 06807 Steel Ring 1
52 13020 DiscforCrankshaft 1
53 06607 HexagonScrew 1
54 13044* Plug,1”BSP 2
55 13151* Plug,1-1/4”BSP 2
ITEM PART DESCRIPTION QTY
1 07759 Crankcase 1
2 13000 OilFillerPlugAssy. 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w/Gasket 1
8 06086 Oil Dipstick Assy. 1
9 01009 O-Ring, (For Dipstick) 1
10 01010 Cylinder Screw 4
11 01011-0400 Spring Ring 5
12 07109 Plug, G1/2” 1
13 07182 Gasket 1
14 07111 Bearing Cover 2
15 07112 Radial Shaft Seal 2
16 07113 O-RingforBearingCover 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 05376 ShaftProtector 1
21A 05377 ShaftGuardHolder 1
22 13242 Crankshaft 1
23 13243 Key 1
24 13340 ConnectingRodAssy. 3
24A 13277 InnerHexScrew 6
24B 13278 SpringWasher 6
25 13341 CrossheadAssy. 3
28 13232 CrossheadPin 3
29A 07125 CenteringSleeve 3
29B 07127 PlungerPipe 3
29C 13031 TensioningScrew 3
29D 07755 CopperRing 3
30 07779 OilScraper 3
31 07133 OilSeal 3
35 13364 SealSleeve 3
Spare Parts List - LP301A-0081
*BSPtoNPTAdapters/Seals(soldseparately)
InletPort=13377(Adapter)/13376(Seal)
DischargePort=13373+(Adapter)/13372(Seal)
+ratedupto3000PSI.Forhigherpressureadapters,contactGiant.
Repair Kits
Plunger Packing Kit
# 09459-0081
For pumps manufactured on or after 4/96
Item Part # Description Qty.
36 13238 LeakageSeal 3
38 07140-0001 O-Ring 3
38A 13241 SupportRing 3
39 12055-0001 O-Ring 3
39A 07693 SupportRing 3
40 06083 Sleeve,Nitrile 3
40A 13366 PressureRing 3
40C 06083-0020 Sleeve,Teon 3
Oil Seal Kit
# 09577
Item Part # Description Qty.
31 07133 OilSeal 3
Valve Kits
# 09196-001
Item Part # Description Qty.
44A 07150-0001 O-Ring 6
44B 06266 SupportRing 3
46A 07064 ValveSeat 3
46B 07063 ValvePlate 3
46C 07062-0100 ValveSpring 3
# 09196A-001
Item Part # Description Qty.
44A 07150-0001 O-Ring 9
44B 06266 SupportRing 3
46A 07064 Valve Seat 6
46B 07063 ValvePlate 6
46C 07062-0100 Valve Spring 6

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 pulling
them upwards out of the
valve casing (43) with a
snap-ring tongs or any
other pull-off 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 plas-
tic stick. 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 107 ft.-lbs. (125
NM)
46A
46D
46B
46C
REPAIR INSTRUCTIONS - LP301A-0081

7
6) Loosen the 8 nuts (49A)
with a 19mm socket and
pulloffvalvecasing(43)
to the front.
TO CHECK SEALS AND PLUNGER PIPE
7) Remove the seal sleeve
(35)from the manifold
and /or crankcase.
8) Remove seal case (37)
fromsealsleeve(35).
9) CheckO-rings(39&38)andsupportrings(39A&
38A)onsealcase(37).
39 39A 37 38A 38
10) Remove leakage seal
(36)fromthesealsleeve.
If worn or damaged re-
place with new seal.
11) Remove the pressure ring (40A), v-sleeves (40/40C),
sleeve, and support ring (40B), from the seal sleeve.
Remove the pressure spring (41). Examine seals careful-
ly and replace if worn. Clean surfaces of seal sleeves
(35)whichcomeincontactwiththecrankcase(1)
andsealingsurfacesofvalvecasing(43).
35 40A 40 40C 40B
REPAIR INSTRUCTIONS - LP301A-0081
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.

8
12) Check plunger surface (29B). If plunger pipe is worn out,
loosen tension screws (29C) with a 15mm socket and
pull off plunger pipe to the front. Clean front surface of
plunger (29B) thoroughly. Apply a small drop of locktite
to tension screw. Put a new crush washer (29D) onto
tension screw. Put a thin coat of glue (Loctite) on the ring
(or ceramic plunger side) and tighten screw to 265 in.-lbs.
(30NM).
29B 29D 29C
13)Replace complete seal
sleeve(35)/sealcase(37)
assembly into crankcase
(1). Make sure that the
weep hole points down-
ward. Note: To replace
the oil seals (31), you
will need to disassemble
the gear end (see in-
structions below).
Weep Hole
14) Place entire manifold/seal
sleeve assembly over the
studsandpushrmlyuntil
seated against the crank-
case.
15) Tighten hex nuts (49A) in a
crosswise pattern (shown
above) to 59 ft.-lbs.
64 2 7
8135
REPAIR INSTRUCTIONS - LP301A-0081

9
Pump Mounting Selection Guide
Bushings
06496-35mm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”)
TO DISMANTLE GEAR END
Afterremovingvalvecasing(43)andplungerpipe(29B),draintheoil.Removethegearcover(4)andboth
bearing covers (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.Con-
necting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removetheoilseals(31)useawoodenrodandsharplyhitdownontheoilsealsfromthecrankcase(1).
Note: when replacing the oil seals, apply a small amount of locktight to the outside edges of each oil seal
before re-inserting them into the crankcase.
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.Re-assembletheuidend(seeinstructions
above).
Position Item# Description Torque Amount
 6 05943 OilSightGlassw/Gasket 354in.-lbs.(40NM)
10 01010 Cylinder Screw 221 in.-lbs. (25 NM)
 12 07109 Plug,1/2”BSP 354in.-lbs.(40NM)
17 07114 Hexagon Screw 221 in.-lbs. (25 NM)
 24A 13277 InnerHexScrew,ConnectingRod 310in.-lbs.(35NM)
 29C 13031 TensionScrew,Plunger 265in.-lbs.(30NM)
48 06077 Plug, Discharge 107 ft.-lbs. (145 NM)
49A 07158 Hexagon Nut, Stud Bolts 59 ft.-lbs. (80 NM)
LP301A-0081 TORQUE SPECIFICATIONS
REPAIR INSTRUCTIONS - LP301A-0081

10
Pump System Malfunction
Preventative Maintenance Check List & Recommended Spare Parts List
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
Recommended Spare Parts
Oil Change (1 Gallon) p/n 01154 X X
Oil Seal Kit (1 kit/pump)
(see page 6 for kit list)
X
Seal Spare Parts (1 kit/pump)
(see page 6 for kit list)
X
Valve Spare Parts (1 kit/pump)
(see page 6 for kit list)
X
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
5
5
5

11
Dimensions Inches (mm) - LP301A-0081

GIANT INDUSTRIES, INC.,900N.WestwoodAve.,P.O.Box3187,Toledo,Ohio43607
PHONE(419)531-4600,FAX(419)531-6836,www.giantpumps.com
 Copyright 2015 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 work-
manship 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(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 WAR-
RANTIES OR MERCHANTABILITY OR FITNESS FOR APARTICULAR PURPOSE AND ALL SUCH
WARRANTIES ARE HEREBY DISCLAIMED AND EXCLUDED BY THE MANUFACTURER.
08/15LP301A-0081.indd