Giant MP Series User manual

MP
Series
Triplex Ceramic Plunger Pump
Operating Instructions/
Repair and Service Manual
Pump Models:
MP4120
MP4124
MP4126
MP4135
MP4130
MP4130HK
Contents:
Installation Instructions: page 2
Pump Specications: page 3
Exploded View: page 4
Parts List / Repair Kits: page 5
Trouble Shooting: page 6
Repair Instructions: page 7-11
Torque Specications: page 11
Dimensions: page 11
Warranty Information: back page
Updated 01/17

2
2
INSTALLATION INSTRUCTIONS
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
essential to provide a safety bypass valve be-
tween 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.
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 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. Cavita-
tion will result in severe damage. Always re-
member to check that all plumbing valves are
open and that pumped media can ow freely to
the inlet of the pump.
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 160 °F (70 °C), it is important to
insure a positive head to the pump to prevent
cavitation. See chart below.
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 SAE 80 or SAE 90 Industrial Gear Oil
(Giant’s p/n 01154)
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.
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.
IMPORTANT OPERATING CONDITIONS
Failure to comply with any of these conditions invalidates the warranty.
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
Consult the factory for special requirements that must be met if the
pump is to operate beyond one or more of the limits specied above.
Horsepower Ratings:
We recommend a 1.15 service factor be specied when selecting an electric motor as the power source.
To compute electric motor horsepower required, use the following formula: HP = (GPM X PSI) / 1450.
The formula to determine the horsepower required for a gas engine is: HP = (GPM X PSI) / 1150.
For the Application of a Hydraulic Motor:
To Determine the Torque of a Hydraulic Motor -- (GPM x PSI x 36.77) / RPM = Torque (in-lbs)
Calculating RPM / GPM of Pump:
A pump must be connected to an electric motor or gas or diesel engine with the correct ratio of pulleys
and belts to attain the required speed and GPM. The use of a Variable Frequency Drive (VFD) may also
be used to control the RPM of a properly sized electric motor when variable ows are required.
(Max. Pump RPM / Rated Pump GPM) x Required Pump GPM = Required Pump RPM
To calculate a pulley diameter one (1) pulley diameter and the required pump RPM must be known:
(Pump RPM x Pump Pulley Diameter) / Motor RPM = Motor Pulley Diameter
(Motor RPM x Motor Pulley Diameter) / Pump RPM = Pump Pulley Diameter
3
Common Specications:
Inlet Pressure ........................ 145 PSI (10 Bar)
Crankshaft Diameter.............. 1.10” (28 mm)
Crankcase Oil Capacity ......... 33.8 . oz. (1 L)
Inlet Ports .............................. (2) 1” NPT
Discharge Ports ..................... (2) 3/4” NPT
Stroke (except MP4126) ........ 1.02” (26 mm)
Stroke (MP4126) ................... 1.2” (30 mm
Weight ................................... 66 lbs (31 kg)
Shaft Rotation............Top of Pulley Toward Fluid End
Materials Used for MP Pumps:
Manifold ........ Aluminum Bronze
Plungers ....... Solid Ceramic Oxide
Valves ........... High Grade Stainless Steel
Seals............. Nitrile with Fabric Reinforcing
Gear End ...... Spheroidal Cast Iron
MP SERIES - PUMP SPECIFICATIONS
Max.
Flow
Max. Pres-
sure
Max.
Speed
Power Re-
quired
Max.
Temperature
Plunger
Diameter
NPSH Re-
quired
Model GPM PSI RPM HP °F in Ft-Head
MP4120 8.9 3625 1450 23.1 160 0.787 24.6
MP4124 12.8 2610 1450 24 160 0.945 27.9
MP4126 17.9 1600 1100 20.4 160 1.2 N/A
MP4135 13.5 1885 1100 18.2 160 1.1 29.5
MP4130 15.4 1600* 1100 17.6 160 1.2 29.5
MP4130HK 15.4 1600 1100 17.6 195 1.2 N/A
U.S. Measurements
Max.
Flow
Max. Pres-
sure
Max.
Speed
Power Re-
quired
Max.
Temperature
Plunger
Diameter
NPSH Re-
quired
Model L/min bar RPM kW °C mm mWs
MP4120 33.8 250 1450 17.2 70 20 7.5
MP4124 48.6 180 1450 17.9 70 24 8.5
MP4126 67.7 110 1100 15.2 70 30 N/A
MP4135 51.2 130 1100 13.6 70 28 9
MP4130 58.2 110* 1100 13.1 70 30 9
MP4130HK 58.2 110 1100 13.1 90 30 N/A
Metric Measurements *Intermittent rating of 2000 PSI
*Intermittent rating of 140 bar

4
4
Exploded View - MP Series

5
ITEM PART # DESCRIPTION QTY.
1 06100 Crankcase 1
2 13000 Oil Filler Cap Assembly 1
4 07243 Cover, Crankcase 1
5 07244 O-Ring, Crankcase Cover 1
8 01008 Oil Dip Stick 1
9 01009 O-Ring, Dip Stick 1
10 01010 Screw, Crankcase Cover 4
11 01011-0400 Spring Washer 4
12 07109 Oil Drain Plug 1
13 06015 O-Ring, Oil Drain Plug 1
14 07245 Bearing Cover 2
15 07247 Seal, Crankshaft 2
16 07627 O-Ring, Bearing Cover 2
17 07114 Hex Screw, Bearing Cover 9
20 07248 Roller Bearing, Tapered 2
20A 07249 Shim 2
20B 06962 Fitting Disc 2
21 05375 Shaft Protector 1
22 07251 Crankshaft (except MP4126) 1
22 04149 Crankshaft (MP4126) 1
23 13331 Key 1
24 07253 Connecting Rod 3
25 07596 Crosshead Complete 3
28 07255 Crosshead Pin 3
29A 07256 Centering Sleeve 3
29B 07262 Ceramic Plunger, 20mm
(MP4120) 3
29B 13046 Ceramic Plunger, 24mm
(MP4124) 3
29B 07261 Ceramic Plunger, 30mm
(MP4130/ MP4130HK) 3
29B 13005 Ceramic Plunger, 28mm
(MP4126/MP4135) 3
29C 13007 Tension Screw 3
29D 07258 Seal Washer 3
30 06136 Flinger 3
31 07260 Crankcase Oil Seal 3
35A 07263 Rear Support Ring (MP4120) 3
35A 06079 Rear Support Ring (MP4124) 3
35B 06064 Rear V-Sleeve (MP4120) 3
35B 06080 Rear V-Sleeve (MP4124) 3
35C 07265 Rear Pressure Ring (MP4120) 3
35C 06081 Rear Pressure Ring (MP4124) 3
35D 07266 Rear O-Ring (MP4120) 3
36 07267 Snap Ring 3
39 07268 Pressure Ring (MP4120) 3
39 06082 Pressure Ring (MP4124) 3
39 07271 Pressure Ring (MP4130/MP4126) 6
39 13013 Pressure Ring (MP4135) 6
40 07322 V-Sleeve (MP4120) 3
40 06083 V-Sleeve (MP4124) 3
40 07272 V-Sleeve (MP4130/MP4126) 6
ITEM PART# DESCRIPTION QTY.
40 05687 V-Sleeve (MP4135) 6
40 06137 V-Sleeve (MP4130HK) 6
40A 07272 V-Sleeve (MP4130HK) 3
41 07270 Support Ring (MP4120) 3
41 06084 Support Ring (MP4124) 3
41 07273 Support Ring (MP4130/MP4126) 6
41 06652 Support Ring (MP4135) 6
41A 07329 Spacer (MP4120) 3
41A 07274 Intermediate Ring
(MP4130/MP4126/MP4135) 3
42 07275 Tension Spring (MP4120/MP4124) 3
42 07353 Tension Spring
(MP4130/MP4126/MP4135) 3
42A 06102 Tension Plug (MP4120/MP4124) 3
42A 06103 Tension Plug
(MP4130/MP4126/MP4135) 3
42B 07332 O-Ring (MP4120/MP4124) 3
42B 07354 O-Ring, Tension Plug
(MP4126/MP4130/MP4135) 3
43 06104 Manifold Head (MP4120/MP4124) 1
43 06105 Manifold Head
(MP4126/MP4130/MP4135) 1
44 07280 Valve Seat 6
44A 07281 O-Ring, Valve Seat 6
45 06791-0100 Valve Plate 6
46 07283 Discharge Valve Spring 3
46A 06959 Inlet Valve Spring
(except MP4124/MP4126) 3
46A 07283 Inlet Valve Spring
(MP4124/MP4126 only) 3
47 07284 Spring Retainer, Discharge 3
48 06108 Plug, (MP4120/MP4124) 3
48 07356 Plug, Brass
(MP4130/MP4126/
MP4135) 3
48A 07332 O-Ring, Plug 3
49 06109 Stud, Manifold 6
49A 07319 Shim, Stud 2
50 07158 Nut, Manifold Stud 6
50A 07159 Spring Washer 6
51 06110 Spacer 3
52 06111 Valve Housing (MP4120/MP4124) 3
52 06112 Valve Housing (MP4130/MP4126
/MP4135) 3
52A 07329 Spacer Ring (MP4120) 3
53 12057 O-Ring (MP4120/MP4124) 3
53 07332 O-Ring
(MP4130/MP4126/MP4135) 3
53A 12027 O-ring (MP4120) 3
54 06115 Spring Retainer, Inlet 3
55 04731 Plug, NPT, 1” 1
56 04732 Plug, NPT, 3/4” 1
57 13020 Disc for Crankshaft 1
MP SERIES PARTS LIST AND REPAIR KITS
5

6
Plunger Packing Kits
MP4120 # 09044
Item Part # Description Qty
35B 06064 Rear V-Sleeve 3
35D 07266 Rear O-Ring 3
40 07322 V-Sleeve 3
42B 07332 O-Ring 3
48A 07332 O-Ring, Plug 3
MP4124 # 09300
Item Part # Description Qty
35B 06080 Rear V-Sleeve 3
40 06083 V-Sleeve 3
42B 07332 O-Ring 3
48A 07332 O-Ring, Plug 3
MP4130/MP4126# 09042
Item Part # Description Qty
40 07272 V-Sleeve 6
42B 07354 O-Ring, Tension Plug 3
48A 07332 O-Ring, Plug 3
MP4135 # 09665
Item Part # Description Qty
40 05687 V-Sleeve 6
42B 07354 O-Ring, Tension Plug 3
48A 07332 O-Ring, Plug 3
MP4130HK # 09664
Item Part # Description Qty
40 06137 V-Sleeve, High Temp 6
40A 07272 V-Sleeve 3
42B 07354 O-Ring, Tension Plug 3
48A 07332 O-Ring, Plug 3
Inlet Valve Kit # 09062
MP4120/MP4124
Item Part # Description Qty
42B 07354 O-Ring Tension Plug 3
42B 07332 O-Ring Tension Plug 3
44 07280 Valve Seat 3
44A 07281 O-Ring, Valve-Seat 3
45 06791-0100 Valve Plate 3
46A 06959 Valve Spring 3
53 12057 O-Ring 3
53A 12027 O-Ring 3
54 06115 Spring Retainer 3
Inlet Valve Kit # 09062
MP4126/MP4130/MP4135
Item Part # Description Qty
42B 07354 O-Ring Tension Plug 3
42B 07332 O-Ring Tension Plug 3
44 07280 Valve Seat 3
44A 07281 O-Ring, Valve-Seat 3
45 06791-0100 Valve Plate 3
46A 06959 Valve Spring 3
53 12057 O-Ring 3
53A 12027 O-Ring 3
54 06115 Spring Retainer 3
Discharge Valve Kit # 09043
Item Part # Description Qty
42B 07332 O-Ring, Tension Plug 3
44 07280 Valve Seat 3
44A 07281 O-Ring 3
45 07282 Valve Plate 3
46 07283 Valve Spring 3
47 07284 Spring Retainer 3
MP SERIES PARTS LIST AND REPAIR KITS

7
REPAIR INSTRUCTION - MP SERIES
To Check Valves
Suction Valve: Screw out plugs (42A). Take out spacer pipe (51) and suction valve adaptor
(52). Push valve parts and as necessary spacer pipe (51) out of suction valve adaptor using a
soft tool.
Check and replace worn parts.
Check O-rings (42B, 44A, 53, 53A) and replace as necessary.
Discharge Valve: Screw out plugs (48). Remove spring tension cap (47), valve spring (46) and
valve plate (45) from the discharge valve. Take out valve seat (44) with a size 2 pull-out device.
Check and replace worn parts.
Check O-rings (44A, 48A) and replace as necessary.
Tighten plugs (42A, 48) to 107 ft.-lbs. (145 Nm).
To Check Seals and Plunger Pipe
Screw out plugs (42A). Loosen nuts (50) and remove valve casing from plungers, pulling it out
to the front. Take out spacer pipe (51), suction valve adaptor (52), tension spring (42) and seal-
unit (39,40,41).
Check surfaces of plunger pipes as damaged surfaces cause fast wear to the seals.
When replacing V-sleeves (40), grease new seals with special grease from pump manufacturer
before installing.
Check O-rings (42B, 44A, 53, 53A) and replace as necessary.
Check Gasket for drip return (40 and/or 35B) and O-ring (35D) after having removed snap ring
(36) and replace as necessary.
If plunger pipe (29B) has to be replaced, loosen tension screw (29C) and remove it together
with the plunger pipe. Check and clean plunger (25) surfaces and install new plunger pipe.
Cover thread of tension screw (29C) with a ne lm of liquid glue and tighten carefully to 22
ft.-lbs. (30 Nm).
Important! Care must be taken that no glue gets between the plunger pipe (29B) and centring
sleeve (29A). The plunger pipe should not be strained by eccentric tightening of tension screw,
nor through dirt or damage to the front surface of the plunger as this could cause the plunger
pipe to break.
Install spacer rings (41A, 52A), tension spring (42), spring tension disc (54), suction valve
adaptor (52) and spacer pipe (51) and then tighten plug (42A) to 107 ft.-lbs. (145 Nm).
Fix valve case by tightening nuts (50) evenly to 59 ft.-lbs. (80 Nm).

8
REPAIR INSTRUCTION - MP SERIES
To Dismantle Gear
Drain oil after dismantling the valve casing (43) and plunger pipes, then screw off crankcase
cover (4) and bearing cover (14).
Loosen con rod screws (24) and push stem of con rod halves as far as possible into the cross-
head guides.
Important! Connecting rods are marked for identication. Do not twist con rod halves. Con
rod is to be reinstalled in the same position on shaft journals.
Whilst turning slightly, hit out the crankshaft to one side with a rubber hammer.
Important! Do not bend the con rod shanks. Check shaft and con rod surfaces, shaft seals
(31) and taper roller bearings (20).
To Reassemble
Using a soft tool, press in the outer bearing ring till the outer edge lines up with the outer edge
of the bearing hole.
Screw off bearing cover together with shaft seal and O-ring. Fit shaft through bearing hole on
the opposite side. Press in outer bearing and tension it inwards with the bearing cover, keeping
the shaft 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) under the bearing cover.
Important! After assembly has been completed, the shaft should turn easily with very little
clearance. Tighten con rod screws (24) to 35NM.

9
9
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 Tempera-
ture
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, cor-
rectly 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
MP SERIES TORQUE SPECIFICATIONS
Position Item# Description Torque Amount
17 07114 Hex Screw, Bearing Cover 125 in.-lbs. (14 Nm)
24 07253 Hex Screw, Connecting Rod 25 ft.-lbs. (28 Nm)
29C 13007 Bolt, Plunger 22 ft.-lbs. (34 Nm)
42A 06102/06103 Plug 107 ft.-lbs. (145 Nm)
50 07158 Nut, Manifold Stud 59 ft.-lbs. (79 Nm)

10
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 Quart) X X
Seal Kit (1 kit/pump) X
(See page 11 for kit lit)
Valve Spare Parts (1 kit/pump) X
(See page 11 for kit list)
MP SERIES TORQUE SPECIFICATIONS
Position Item# Description Torque Amount
17 07114 Hex Screw, Bearing Cover 125 in.-lbs. (14 Nm)
24 07253 Hex Screw, Connecting Rod 25 ft.-lbs. (28 Nm)
29C 13007 Bolt, Plunger 22 ft.-lbs. (34 Nm)
42A 06102/06103 Plug 107 ft.-lbs. (145 Nm)
50 07158 Nut, Manifold Stud 59 ft.-lbs. (79 Nm)

11
MP SERIES DIMENSIONS - Inches (mm)

GIANT INDUSTRIES, INC., 900 N. Westwood Ave., Toledo, Ohio 43607
PHONE [phone], FAX [phone], www.giantpumps.com
© Copyright 2012 Giant Industries, Inc. 06/12 MP Series.indd
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 self-service car wash applications, the dis-
charge manifolds are guaranteed for the life of the pump. Our other pump parts,
used in portable pressure washers and in car wash applications, 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 follow-
ing 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 prod-
ucts 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 pro-
vided 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 A PARTICULAR PURPOSE AND ALL
SUCH WARRANTIES ARE HEREBY DISCLAIMED AND EXCLUDED BY THE MANUFACTURER.