Giant LP301A-5100 User manual

Triplex Ceramic
Plunger Pump
Operating Instructions/
Manual
Model
LP301A-5100
Contents:
InstallationInstructions: page 2
Specifications: page 3
Exploded View: page 4
Parts List / Kits: page 5
RepairInstructions: page 6-9
Pump Mounting Selection Guide: page 9
TorqueSpecifications: page 9
TroubleShooting/Preventative
Maintenance Check-List
& Recommended Spare Parts List:page 10
Dimensions: page 11
WarrantyInformation: 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 ob-
tained 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 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
crankcase so that oil level is between the two
lines on the oil dipstick. DO NOT OVERFILL.
Use SAE 85-140 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.
NOTE: Contact Giant Industries for Service School Information. Phone: [phone]

3
Specifications
Model LP301A-5100
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 manufactur-
ers.
1.Select GPM required, then select appropri-
ate 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.
HORSEPOWERINFORMATION
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
U.S. (Metric)
Ratings ......................................................... 14.1 GPM ................(68 LPM)
Discharge Pressure ....................................... 4000 PSI ..................(275 bar)
RPM...............................................................................................1000 RPM
Inlet Pressure..................................................................................Up to 140 PSI
Plunger Diameter.......................................... 0.94”........................24 mm
Stroke........................................................... 1.65”........................42 mm
Crankcase Oil Capacity ................................ 100 fl.oz. ..................(3 liters)
Temperature of Pumped Fluids ..................... Up to 140 oF.............(60 oC)
Inlet Port ........................................................................................3 x 1-1/4" FNPT
Discharge Port ................................................................................3 x 1" FNPT
Crankshaft Mounting ......................................................................Either Side
Shaft Rotation............................................... Top of Pulley Towards Fluid End
Weight.......................................................... 110 lbs. ....................(49.9 kg)
Crankshaft Diameter.......................................................................35 mm
LP301A-5100 PULLEY SELECTION AND HORSEPOWER
REQUIREMENTS
PUMP
PULLEY
MOTOR
PULLEY
RPM GPM 2500 PSI 3000 PSI 3500 PSI 4000 PSI
12.75" 3.95" 500 7.05 12.2 14.7 17.1 19.6
12.75" 4.95" 640 9.02 15.6 18.8 21.9 25.1
12.75" 5.75" 750 10.57 18.4 22.0 25.7 29.4
12.75" 6.15" 805 11.35 19.7 23.6 27.6 31.5
12.75" 6.55" 865 12.2 21.2 25.4 29.6 33.9
12.75" 6.95" 940 13.25 23.0 27.6 32.2 36.8
12.75" 7.50" 1000 14.1 24.5 29.4 34.3 39.2
NPSHR Chart

4
Exploded View - LP301A-5100

LP301A-5100 PARTS LIST
ITEM PART DESCRIPTION QTY
30 07779 Oil Scraper 3
31 07133 Oil Seal 3
35 13364-0100 Seal Sleeve 3
36 13238 Leakage Seal 3
37 13240-0100 Seal Case 3
38 07140 O-Ring, Seal Case 3
38A 13241 Support Ring for 38 3
39 12055 O-Ring 3
39A 07693 Support Ring for 39 3
40 06083 V-Sleeve 6
40A 13366 Pressure Ring 3
40B 13438 Guide Ring for 40 3
41 07338 Pressure Spring 3
43 13040-5000 Valve Casing 1
44A 07150 O-Ring 9
44B 06266 Support Ring for O-Ring 3
45 06078 Compression Spring 3
46 07060-0100 Valve Assy., Complete 6
46A 07064-0100 Valve Seat 6
46B 07063-0100 Valve Plate 6
46C 07750-0100 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
52 13020 Disc for Crankshaft 1
53 06607 Hexagon Screw 1
54 07756 Plug, G 1" 2
55 06982 Plug, G 1-1/4" 2
LP301A-5100 REPAIR KITS
Valve Kit
# 09196-0100
Item Part # Description Qty.
46A 07064-0100 Valve Seat 3
46B 07063-0100 Valve Plate 3
46C 07750-0100 Valve Spring 3
44A 07150 O-Ring 6
44B 06266 Support Ring 3
ITEM PART DESCRIPTION QTY
107759 Crankcase 1
213000 Oil Filler Plug Assy... 1
406085 Crankcase Cover 1
507104 O-ring, Crankcase Cover 1
607186 Oil Sight Glass w/Gasket 1
707187 Gasket (For Sight Glass) 1
806086 Oil Dipstick Assy. 1
901009 O-Ring, (For Dipstick) 1
10 08093 Cylinder Screw 4
11 08094 Spring Ring 5
12 12137 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 08095 Hexagon Screw with washer 8
20 07116 Taper Roller Bearing 2
20A 07117 Fitting Disc 1-2
20B 13001 Fitting Disc (may not be present) 1-3
21 07118 Shaft Protector 1
22 13242 Crankshaft 1
23 13243 Woodruff 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 07131-0100 Tensioning Screw 3
29D 07755-0100 Copper Ring 3
Plunger Packing Kit
# 09459
Item Part # Description Qty.
36 13238 Leakage Seal 3
38 07140 O-Ring 3
38A 13241 Support Ring 3
39 12055 O-Ring 3
39A 07693 Support Ring 3
40 06083 V-Sleeve 6
40A 13366 Pressure Ring 3
5

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 film of oil before reassembling. This step
will help ensure proper fit, 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 ten-
sion spring (45).
3) Take out discharge valve as-
semblies (46) by pulling
them upwards out of the
valve casing (43) with a
snap-ring tongs or any other
pull-off device. Then re-
move 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. Check sealing surface
and replace worn parts.
Reassemble with new o-
rings (44A) if possible and
oil them before installing.
5) Tighten up tension plugs
(48) to 107 ft.-lbs.
46A
46D
46B
LP301A-5100 REPAIR INSTRUCTIONS
46C

11) Remove the pressure ring (40A), v-sleeves (40), and
support ring (40B), from the seal sleeve. Remove the pressure
spring (41). Examine seals carefully 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 40 40B
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
NOTE: Always take time to lubricate all metal and non-metal parts with a light film of oil before reassembling. This step
will help ensure proper fit, at the same time protecting the pump non-metal parts (elastomers) from cutting and scoring.
7) Remove the seal sleeve
(35) from the manifold
and /or crankcase.
8) Remove seal case (37) from
seal sleeve (35).
LP301A-5100 REPAIR INSTRUCTIONS
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 replace with
new seal.

8
LP301A-5100 REPAIR INSTRUCTIONS
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.
29B 29D 29C
13) Replace complete seal sleeve
(35)/seal case (37) assembly
into crankcase (1). Make
sure that the weep hole
points downward. Note: To
replace the oil seals (31),
you will need to disas-
semble the gear end (see
instructions below).
Weep Hole
14) Place entire manifold/seal
sleeve assembly over the
studs and push firmly until
seated against the crankcase.
15) Tighten hex nuts (49A) in a
crosswise pattern (shown
above) to 59 ft.-lbs.
64 2 7
81 3 5

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”)
9
LP301A-5100 REPAIR INSTRUCTIONS
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 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 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 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 clearance.
Tighten connecting rod screws (24A) to 310 in.-lbs. Re-assemble the fluid end (see instructions above).
Position Item# Description Torque Amount
24A 13277 Inner Hex Screw, Connecting Rod 310 in.-lbs.
29C 07131-0100 Tension Screw, Plunger 265 in.-lbs.
48 06077-0100 Plug, Discharge 107 ft.-lbs.
49A 07158 Hexagon Nut, Stud Bolts 59 ft.-lbs.
LP301A-5100 TORQUE SPECIFICATIONS

10
PUMPSYSTEMMALFUNCTION
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 Cleanstrainer
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, Refill crankcase
oil with recommended lubricant
Cavitation Check inlet lines for restrictions
and/or proper sizing
Rough/Pulsating Worn packing Replace packing
Operationwith Inletrestriction 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
Pump Pressure as Restricted discharge plumbing Re-size discharge plumbing to Drop at
gun flow rate of pump
Rated, Pressure
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
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 XX
Seal Spare Parts (1 kit/pump) X
Valve Spare Parts (1 kit/pump) X

LP301A-5100 DIMENSIONS - Inches (mm)
11

GIANT INDUSTRIES, INC., 900 N. Westwood Ave., P.O. Box 3187, Toledo, Ohio 43607
PHONE [phone], FAX [phone], www.giantpumps.com
 Copyright 2003 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 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.
Thiswarrantyislimitedtorepairorreplacementofpumpsandaccessoriesofwhichthe 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 WAR-
RANTIESORMERCHANTABILITYORFITNESSFORAPARTICULARPURPOSEANDALLSUCH
WARRANTIES ARE HEREBY DISCLAIMED AND EXCLUDED BY THE MANUFACTURER.
5/03 LP301A-5100.PM6