Giant LP301A-5100 User's Manual
Contents
1. Apply a small drop of locktite to tension screw Put sure that the weep hole a new crush washer 29D onto tension screw Put a thin coat points downward Note To of glue Loctite on the ring or ceramic plunger side and replace the oil seals 31 tighten screw to 265 in lbs you will need to disas semble the gear end see instructions below 14 Place entire manifold seal 15 Tighten hex nuts 49A in a sleeve assembly over the crosswise pattern shown studs and push firmly until above to 59 ft Ibs seated against the crankcase 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 small2. 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 A PARTICULAR PURPOSE AND ALL SUCH WARRANTIES ARE HEREBY DISCLAIMED AND EXCLUDED BY THE MANUFACTURER PHONE 419 531 4600 FAX 419 531 6836 www giantpumps com Copyright 2003 Giant Industries Inc GIANT INDUSTRIES INC 900 N Westwood Ave P O Box 3187 Toledo Ohio 43607 5 03 LP301A 5100 PM6
3. Drop at 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 amp Recommended Spare Parts List Oil Level Quality Daily Weekly 50hrs Every 500 hrs Every 1500 hrs Every 3000 hrs Oil Leaks Water Leaks Belts Pulley X Plumbing X Recommended Spare Parts Oil Change 1 Gallon p n 1154 X X Seal Spare Parts 1 kit pump Valve Spare Parts 1 kit pump 10 LP301A 5100 DIMENSIONS Inches mm 15 2 385 a T amp 80Z zg Hole M8 i 6 3 160 10 3 262 son Discharge 4 8 123 13 6 345 Connection 3x 1 NPT Ts Van ge WAG Ae D oh 2 0 51 aX N 2 2 55 T Sp Inlet Connection 3 x 1 1 4 NPT ui oO oO he O Mm d 1 6 41 5 4 x Mle 8 3 210 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
4. Seal Case O Ring Seal Case Support Ring for 38 O Ring Support Ring for 39 V Sleeve Pressure Ring Guide Ring for 40 Pressure Spring Valve Casing O Ring Support Ring for O Ring Compression Spring Valve Assy Complete Valve Seat Valve Plate Valve Spring Spacer Pipe Plug Stud bolt Hexagon Nut Disc Disc for Crankshaft Hexagon Screw Plug G 1 Plug G 1 1 4 Valve Kit 09196 0100 Item Part Description 46A 07064 0100 Valve Seat 46B 07063 0100 Valve Plate 46C 07750 0100 Valve Spring 44A 07150 O Ring 44B 06266 Support Ring Nu nmmwannaanawue uuunauuuwuuwuu lt WO WW W LP301A 5100 REPAIR INSTRUCTIONS 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 TO CHECK VALVES 1 Loosen and remove tension 2 Remove the support ring 3 Take out discharge valve as plugs 48 with a 36mm 44B o ring 44A and ten semblies 46 by pulling socket wrench sion spring 45 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 5 Tighten up tension plugs from spacer pipe 46D by 48 to 107 ft Ibs lightly hitting the valve plate 46B with a plastic stick Check sealin
5. 13341 13232 07125 07127 07131 0100 07755 0100 LP301A 5100 PARTS LIST DESCRIPTION Crankcase Oil Filler Plug Assy Crankcase Cover O ring Crankcase Cover Oil Sight Glass w Gasket Gasket For Sight Glass Oil Dipstick Assy O Ring For Dipstick Cylinder Screw Spring Ring Plug G1 2 Gasket Bearing Cover Radial Shaft Seal O Ring for Bearing Cover OTY 1 1 1 1 1 1 1 1 4 5 1 1 2 2 2 Hexagon Screw with washer 8 Taper Roller Bearing Fitting Disc 2 1 2 Fitting Disc may not be present 1 3 Shaft Protector Crankshaft Woodruff Key Connecting Rod Assy Inner Hex Screw Spring Washer Crosshead Assy Crosshead Pin Centering Sleeve Plunger Pipe Tensioning Screw Copper Ring 1 WwW WW WW DW DW Lu ra Fa ITEM 30 31 35 36 37 38 38A 39 39A 40 40A 40B 41 43 44A 44B 45 46 46A 46B 46C 46D 48 49 49A 49B 52 53 54 55 PART 07779 07133 13364 0100 13238 13240 0100 07140 13241 12055 07693 06083 13366 13438 07338 13040 5000 07150 06266 06078 07060 0100 07064 0100 07063 0100 07750 0100 07066 06077 0100 07157 07158 07159 13020 06607 07756 06982 LP301A 5100 REPAIR KITS Plunger Packing Kit 09459 Item Part Description 36 13238 Leakage Seal 38 07140 O Ring 38A 13241 Support Ring 39 12055 O Ring 39A 07693 Support Ring 40 06083 V Sleeve 40A 13366 Pressure Ring wenn DESCRIPTION Oil Scraper Oil Seal Seal Sleeve Leakage Seal
6. Model Triplex Ceramic Plunger Pump Operating Instructions Manual LP301A 5100 Contents Installation Instructions Specifications Exploded View Parts List Kits Repair Instructions Pump Mounting Selection Guide Torque Specifications Trouble Shooting Preventative Maintenance Check List amp Recommended Spare Parts List Dimensions Warranty Information page 2 page 3 page 4 page 5 page 6 9 page 9 page 9 page 10 page 11 back page INSTALLATION INSTRUCTIONS 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 140 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 flow rate to prevent line pressure loss to the work area It is essential to provide a safet
7. 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 LP301A 5100 TORQUE SPECIFICATIONS Position Item Description Torque Amount 24A 13277 Inner Hex Screw Connecting Rod 310 in Ibs 29C 07131 0100 Tension Screw Plunger 265 in Ibs 48 06077 0100 Plug Discharge 107 ft Ibs 49A 07158 Hexagon Nut Stud Bolts 59 ft Ibs Pump Mounting Selection Guide Bushings 06496 35 mm H Bushing Pulley amp 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 MALFUNCTION The Pressur
8. cified when selecting an electric motor as the power source To compute specific pump horsepower requirements use the following formula Specifications Model LP301A 5100 U S Metric Ratings ennn aa a aLa E eai 14 1 GPM 68 LPM Discharge Pressure nnen nnee 4000 PSI 275 bar RPM innemen intended erste veren 1000 RPM Jet tege ee en Eege eege Up to 140 PSI Plunger Diameter nennen RE 24 mm STOK enee OI ese esses 42 mm Crankcase Oil Capacity 100 floz 3 liters Temperature of Pumped Fluids Up to 140 F 60 C ru Ge E 3 x 1 1 4 FNPT Discharge Port vanette RRA 3 x 1 FNPT Crankshaft Mounting neven eennnneeeenenveeevennneernnnen Either Side Shaft Rotation eenen isiin Top of Pulley Towards Fluid End Weighted de TIO IDS irinse 49 9 kg Crankshaft Diameter neccessaire iesenii iseiti 35 mm PULLEY INFORMATION Meters Water Feet Hean Vescosity Comtipone HP GPM X PSI 1440 LP301A 5100 PULLEY SELECTION AND HORSEPOWER REQUIREMENTS PUMP MOTOR 16 N 48 20B May not be present Exploded View LP301A 5100 20A 20B 21 22 23 24 24A 24B 25 28 29A 29B 29C 29D PART 07759 13000 06085 07104 07186 07187 06086 01009 08093 08094 12137 07182 07111 07112 07113 08095 07116 07117 13001 07118 13242 13243 13340 13277 13278
9. e and or the Delivery Drops Water in crankcase Noisy Operation Rough Pulsating Operation with Pressure Drop Pump Pressure as gun Rated Pressure Excessive Leakage High Crankcase Temperature PUMP SYSTEM MALFUNCTION 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 pump for restrictions 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 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
10. 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 Normal wear and tear to standard wear parts Use of repair parts other than those manufactured or authorized by Giant Improper use of the product as a component part Changes or modifications made by the customer or third party The operation of pumps and or accessories exceeding the specifications set forth in the Operations Manuals provided by Giant Industries Inc DAR WN 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
11. g surface and replace worn parts Reassemble with new o rings 44A if possible and oil them before installing LP301A 5100 REPAIR INSTRUCTIONS 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 TO CHECK SEALS AND PLUNGER PIPE 6 Loosen the 8 nuts 49 A 7 Remove the seal sleeve 8 Remove seal case 37 from with a 19mm socket and 35 from the manifold seal sleeve 35 pull off valve casing 43 and or crankcase to the front 9 Check O rings 39 amp 38 and support rings 39A amp 38A on seal case 37 10 Remove leakage seal 36 11 Remove the pressure ring 40A v sleeves 40 and from the seal sleeve If worn support ring 40B from the seal sleeve Remove the pressure or damaged replace with spring 41 Examine seals carefully and replace if worn Clean new seal surfaces of seal sleeves 35 which come in contact with the crankcase 1 and sealing surfaces of valve casing 43 LP301A 5100 REPAIR INSTRUCTIONS EI O 29B 29D 12 Check plunger surface 29B If plunger pipe is worn out 13 Replace complete seal sleeve loosen tension screws 29C with a 15mm socket and pull off 35 seal case 37 assembly plunger pipe to the front Clean front surface of plunger 29B into crankcase 1 Make thoroughly
12. tial hazard it can cause serious injury IMPORTANT OPERATING CONDITIONS Failure to comply with any of these conditions invalidates the warranty 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 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 NOTE Contact Giant Industries for Service School Information Phone 419 531 4600 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 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 HORSEPOWER INFORMATION We recommend that a 1 1 service factor be spe
13. y 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 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 Finally remember that high pressure operation in a pump system has many advantages But if it is used carelessly and without regard to its poten
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