Triplex Ceramic
Plunger Pump
Operating Instructions/
Manual
Model
LP301A-5100
Contents:
Installation Instructions:
Specifications:
Exploded View:
Parts List / Kits:
Repair Instructions:
page 2
page 3
page 4
page 5
page 6-9
Pump Mounting Selection Guide:
page 9
Torque Specifications:
page 9
Trouble Shooting/Preventative
Maintenance Check-List
& Recommended Spare Parts List:
Dimensions:
page 10
page 11
back page
Warranty Information:
Download from Www.Somanuals.com. All Manuals Search And Download.
Specifications
Model LP301A-5100
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
NPSHR Chart
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.
HORSEPOWER INFORMATION
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
LP301A-5100 PULLEY SELECTION AND HORSEPOWER
REQUIREMENTS
PUMP
PULLEY PULLEY
MOTOR
RPM
GPM
2500 PSI 3000 PSI 3500 PSI 4000 PSI
12.75"
12.75"
12.75"
12.75"
12.75"
12.75"
12.75"
3.95"
4.95"
5.75"
6.15"
6.55"
6.95"
7.50"
500
640
750
805
865
940
1000
7.05
9.02
10.57
11.35
12.2
12.2
15.6
18.4
19.7
21.2
23.0
24.5
14.7
18.8
22.0
23.6
25.4
27.6
29.4
17.1
21.9
25.7
27.6
29.6
32.2
34.3
19.6
25.1
29.4
31.5
33.9
36.8
39.2
13.25
14.1
3
Download from Www.Somanuals.com. All Manuals Search And Download.
4
Download from Www.Somanuals.com. All Manuals Search And Download.
LP301A-5100 PARTS LIST
ITEM
1
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
13341
13232
07125
07127
07131-0100
07755-0100
DESCRIPTION
QTY
1
ITEM PART
DESCRIPTION
Oil Scraper
QTY
3
Crankcase
30
07779
2
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
1
31
07133
Oil Seal
3
4
1
35
13364-0100
13238
Seal Sleeve
3
5
1
36
Leakage Seal
Seal Case
3
6
1
37
13240-0100
07140
3
7
1
38
O-Ring, Seal Case
Support Ring for 38
O-Ring
3
8
1
38A
39
13241
3
9
1
12055
3
10
11
12
13
14
15
16
17
20
20A
20B
21
22
23
24
24A
24B
25
28
29A
29B
29C
29D
4
39A
40
07693
Support Ring for 39
V-Sleeve
3
Spring Ring
5
06083
6
Plug, G1/2"
1
40A
40B
41
13366
Pressure Ring
Guide Ring for 40
Pressure Spring
Valve Casing
O-Ring
3
Gasket
1
13438
3
Bearing Cover
2
07338
3
Radial Shaft Seal
O-Ring for Bearing Cover
Hexagon Screw with washer
Taper Roller Bearing
Fitting Disc
2
43
13040-5000
07150
1
2
44A
44B
45
9
8
06266
Support Ring for O-Ring
Compression Spring
Valve Assy., Complete
Valve Seat
3
2
06078
3
1-2
46
07060-0100
07064-0100
07063-0100
07750-0100
07066
6
Fitting Disc (may not be present) 1-3
46A
46B
46C
46D
48
6
Shaft Protector
Crankshaft
1
1
1
3
6
6
3
3
3
3
3
3
Valve Plate
6
Valve Spring
Spacer Pipe
6
Woodruff Key
Connecting Rod Assy.
Inner Hex Screw
Spring Washer
Crosshead Assy.
Crosshead Pin
Centering Sleeve
Plunger Pipe
6
06077-0100
07157
Plug
3
49
Stud bolt
8
49A
49B
52
07158
Hexagon Nut
Disc
8
07159
8
13020
Disc for Crankshaft
Hexagon Screw
Plug, G 1"
1
53
06607
1
54
07756
2
Tensioning Screw
Copper Ring
55
06982
Plug, G 1-1/4"
2
LP301A-5100 REPAIR KITS
Plunger Packing Kit
Valve Kit
# 09196-0100
# 09459
Item
36
Part # Description
13238 Leakage Seal
07140 O-Ring
Qty.
Item
46A
46B
46C
44A
44B
Part #
Description
Qty.
3
3
3
3
3
6
3
07064-0100 Valve Seat
07063-0100 Valve Plate
07750-0100 Valve Spring
07150
06266
3
3
3
6
3
38
38A
39
13241 Support Ring
12055 O-Ring
O-Ring
Support Ring
39A
40
07693 Support Ring
06083 V-Sleeve
40A
13366 Pressure Ring
5
Download from Www.Somanuals.com. All Manuals Search And Download.
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
44B
44A
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.
2) Remove the support ring
(44B), o-ring (44A) and ten-
sion spring (45).
1) Loosen and remove tension
plugs (48) with a 36mm
socket wrench.
46C
46A
46B
46D
4) Loosen valve seats (46A)
and valve spring (46C)
5) Tighten up tension plugs
(48) to 107 ft.-lbs.
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.
6
Download from Www.Somanuals.com. All Manuals Search And Download.
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 (49A)
with a 19mm socket and
pull off valve casing (43)
to the front.
8) Remove seal case (37) from
seal sleeve (35).
7) Remove the seal sleeve
(35) from the manifold
and /or crankcase.
39
39A
37
38A
38
9) Check O-rings (39 & 38) and support rings (39A & 38A)
on seal case (37).
35
40A
40
40
40B
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).
10) Remove leakage seal (36)
from the seal sleeve. If worn
or damaged replace with
new seal.
7
Download from Www.Somanuals.com. All Manuals Search And Download.
LP301A-5100 REPAIR INSTRUCTIONS
29B
29D
29C
Weep Hole
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.
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).
6
8
7
5
4
1
2
3
15) Tighten hex nuts (49A) in a
crosswise pattern (shown
above) to 59 ft.-lbs.
14) Place entire manifold/seal
sleeve assembly over the
studs and push firmly until
seated against the crankcase.
8
Download from Www.Somanuals.com. All Manuals Search And Download.
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).
LP301A-5100 TORQUE SPECIFICATIONS
Position
24A
Item#
13277
07131-0100
06077-0100
07158
Description
Torque Amount
310 in.-lbs.
Inner Hex Screw, Connecting Rod
Tension Screw, Plunger
Plug, Discharge
29C
48
49A
265 in.-lbs.
107 ft.-lbs.
59 ft.-lbs.
Hexagon Nut, Stud Bolts
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
Download from Www.Somanuals.com. All Manuals Search And Download.
PUMP SYSTEM MALFUNCTION
MALFUNCTION
CAUSE
REMEDY
The Pressure and/
or the Delivery
Drops
Worn packing seals
Broken valve spring
Belt slippage
Replace packing seals
Replace spring
Tighten or Replace belt
Replace nozzle
Worn or Damaged nozzle
Fouled discharge valve
Fouled inlet strainer
Worn or Damaged hose
Worn or Plugged relief valve on pump
Cavitation
Clean valve assembly
Cleanstrainer
Repair/Replace hose
Clean, Reset, and Replace worn parts
Check suction lines on inlet of
pump for restrictions
Unloader
Check for proper operation
Water in crankcase
Noisy Operation
High humidity
Worn seals
Reduce oil change interval
Replace seals
Worn bearings
Cavitation
Replace bearings, Refill crankcase
oil with recommended lubricant
Check inlet lines for restrictions
and/or proper sizing
Rough/Pulsating
Operation with
Pressure Drop
Worn packing
Inlet restriction
Replace packing
Check system for stoppage, air
leaks, correctly sized inlet
plumbing to pump
Accumulator pressure
Unloader
Cavitation
Recharge/Replace accumulator
Check for proper operation
Check inlet lines for restrictions
and/or proper size
Pump Pressure as
gun
Rated, Pressure
Restricted discharge plumbing
Re-size discharge plumbing to Drop at
flow rate of pump
Excessive
Leakage
Worn plungers
Replace plungers
Worn packing/seals
Excessive vacuum
Cracked plungers
Inlet pressure too high
Adjust or Replace packing seals
Reduce suction vacuum
Replace plungers
Reduce inlet pressure
High Crankcase
Temperature
Wrong Grade of oil
Improper amount of oil in crankcase
Giant oil is recommended
Adjust oil level to proper amount
Preventative Maintenance Check-List & Recommended Spare Parts List
Check
Daily
Weekly
50hrs
Every
500 hrs
Every
1500 hrs
Every
3000 hrs
Oil Level/Quality
Oil Leaks
Water Leaks
Belts, Pulley
Plumbing
X
X
X
X
X
Recommended Spare Parts
Oil Change (1 Gallon) p/n 1154
Seal Spare Parts (1 kit/pump)
Valve Spare Parts (1 kit/pump)
X
X
X
X
10
Download from Www.Somanuals.com. All Manuals Search And Download.
LP301A-5100 DIMENSIONS - Inches (mm)
11
Download from Www.Somanuals.com. All Manuals Search And Download.
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.
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.
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 (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.
GIANT INDUSTRIES, INC., 900 N. Westwood Ave., P.O. Box 3187, Toledo, Ohio 43607
Ó Copyright 2003 Giant Industries, Inc.
5/03 LP301A-5100.PM6
Download from Www.Somanuals.com. All Manuals Search And Download.
|