Check oil level prior to starting and ensure
trouble free water supply.
IMPORTANT! If there is a danger of frost,
the water in the pump and in the pump ttings
(particularly the unloader valve) must be emptied. The second discharge port can also be
used and the pump run “dry” for 1-2 minutes
for this purpose.
Oil: Use only 118 uid ounces (3.5 L) of SAE
90 Industrial gear lube oil. (Giant’s p/n 01154)
Initial change after 50 operating hours and
then every 1000 operating hours, or after one
year if used less.
Caution! When operating in damp places or
with high temperature uctuations, condensate (frothy oil) might occur in the gear box.
In this situation, change the oil immediately.
Keep NPSH under control.
Maximum input pressure is 145 PSI (10 bar),
the maximun suction head is -4.35 PSI (-0.3
bar). Make sure that suction pulsation is suf-
ciently dampened. Water column resonance
must be avoided.
Safety Rules
Pump operation without safety valve as well
as any excess in temperature or speed limits
automatically voids the warranty. The safety
valve must be regulated in accordance with
the guidelines for liquid spraying units so that
the admissible operating pressure can not be
exceeded by more than 10%.
When the pump is in operation, the open shaft
end must be covered up by a shaft protector
(21). For direct drive operations, the driven
shaft side and coupling must have a guard
over the connected area.
Pressure in discharge line and in pump must
be at zero before any maintenance to the
pump takes place. Close the uid supply to
the inlet port(s). Disconnect fuses to ensure
that the driving motor does not accidentally get
switched on. Make sure that all parts on the
pressure side of the unit are vented and re-
lled, with pressure at zero, before starting the
pump.
In order to prevent air, or air/water mixture
being absorbed and to prevent cavitation occurring, the pump-npshr, positive suction head
and water temperature must be kept under
control.
Required NPSH refers to water: Specic
weight 0.0624 lb/ft3 (1kg/dm3), viscosity 1°E at
maximum permissible revolutions.
Cavitation and/or compression of gases
lead to uncontrollable pressure kicks which
can ruin pump and unit parts and also be
dangerous to the operator or anyone standing nearby.
Giant pumps are suitable for pumping clean
water and other non-aggressive or abrasive
media with a specic weight similar to water.
Before pumping other liquids - especially
inammable, explosive and toxic media -
the pump manufacturer must under all circumstances be consulted with regard to the
resistance of the pump material. It is the responsibility of the equipment manufacturer
and/or operator to ensure that all pertinent
safety regulations are adhered to.
NOTE: Contact Giant Industries for Service School Information. Phone: (419)-531-4600
Discharge Pressure ...................................................................... 3000 PSI ......................................... 200 Bar
Inlet Pressure ............................................................................... -4.35 to 87 PSI ...................... -0.3 to 6.0 Bar
Speed ...................................................................................................................................... Up to 1000 RPM
Plunger Diameter .......................................................................... 1.10” .................................................. 28 mm
Stroke ............................................................................................ 1.65” .................................................. 42 mm
Crankcase Oil Capacity ................................................................ 118 .oz. ................................................ 3.5 L
Temperature of Pumped Fluids @ 1000 RPM ............................... 140 o F ................................................. 60 oC
Temperature of Pumped Fluids @ 500 RPM ................................. 160 o F ..................................................70 oC
Inlet Port .................................................................................................................................... (3) x 1-1/2” BSP
Discharge Port ................................................................................................................................. (3) x 1” BSP
Crankshaft Mounting ......................................................................................................................... Either Side
Shaft Rotation .................................................................................................... Top of Pulley Towards Fluid End
Weight .......................................................................................... 119 lbs. ................................................ 54 kg
Crankshaft Diameter ................................................................................................................................ 35 mm
Discharge Pressure ...................................................................... 1740 PSI .......................................... 120 Bar
Inlet Pressure ............................................................................... -4.35 to 87 PSI .......................-0.3 to 6.0 Bar
Speed ...................................................................................................................................... Up to 1000 RPM
Plunger Diameter .......................................................................... 1.42” .................................................. 36 mm
Stroke ............................................................................................ 1.65” .................................................. 42 mm
Crankcase Oil Capacity ................................................................ 118 .oz. ................................................ 3.5 L
Temperature of Pumped Fluids @ 1000 RPM ............................... 140 o F ................................................. 60 oC
Temperature of Pumped Fluids @ 500 RPM ................................. 160 o F ..................................................70 oC
Inlet Port .................................................................................................................................... (3) x 1-1/2” BSP
Discharge Port ................................................................................................................................. (3) x 1” BSP
Crankshaft Mounting ......................................................................................................................... Either Side
Shaft Rotation .................................................................................................... Top of Pulley Towards Fluid End
Weight .......................................................................................... 119 lbs. ................................................ 54 kg
Crankshaft Diameter ................................................................................................................................ 35 mm
LP200 HORSEPOWER REQUIREMENTS
RPM GPM 1000 PSI 1500 PSI 2000 PSI 3000 PSI
5009.66.69.913.219.9
64012.28.412.616.825.2
75014.39.914.819.729.6
80515.410.615.921.231.9
86516.511.417.122.834.1
92017.612.118.224.336.4
1000 19.113.219.826.339.5
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 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.
LP121A HORSEPOWER REQUIREMENTS
RPM GPM500 PSI1000 PSI 1500 PSI 1740 PSI
50016.35.611.216.919.6
64020.87.214.421.525.0
75024.48.416.825.229.3
80526.29.018.127.131.4
86528.19.719.429.133.7
92029.910.320.630.935.9
1000 32.511.222.433.639.0
HORSEPOWER INFORMATION
We recommend that a 1.1 service factor be speci-
ed when selecting an electric motor as the power
source. To compute specic pump horsepower
requirements, use the following formula:
HP = (GPM X PSI) / 1450
3
Exploded View - LP121A-5100, LP200-5100, and LP250-5100
Important! The stainless steel valve plugs (48) can seize when being screwed out of the casing.
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)
4
4
LP121A-5100, LP200-5100, and LP250-5100 Parts List
Plunger Diameter .................................................................1.26” ......................................32 mm
Stroke ...................................................................................1.65” .......................................42 mm
Crankcase Oil Capacity ............................................................. 118 .oz. ...................................... 3.5 L
Temperature of Pumped Fluids ................................................ 140 o F .........................................60 o C
Inlet Port ................................................................................................................. 3 x 1-1/2” BSP
Discharge Port ........................................................................................................................ 3 x 1” BSP
Crankshaft Mounting .............................................................................................................. Either Side
Shaft Rotation .....................................................................................Top of Pulley Towards Fluid End
Weight .................................................................................119 lbs. ........................................ 54 kg
Crankshaft Diameter.............................................................................................................35 mm
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 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 1.1 service factor be
specied when selecting an electric motor
as the power source. To compute specic
pump horsepower requirements, use the
following formula:
HP = (GPM X PSI) / 1440
6
LP121A-5100, LP200-5100, and LP250-5100 - Repair Instructions
44A 44B 45
1. With a 30mm wrench,
remove the 3 plugs (48).
46A 46B 46D
4. Loosen valve seats (46A) 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) and oil them before installing. Tighten
up tension plugs (48) to 107 ft.-lbs. (145 NM).
2. Remove the compression
spring (45), O-rings and
support rings (44A & 44B).
3. Remove the complete
valve assembly (46A-46D)
with valve pullers.
5. Loosen the 8 nuts (49A)
with a 19mm wrench. Tap
the back of the manifold
(43) with a rubber mallet
to dislodge and slide off
the studs (49).
6. Pull seal sleeves (35) out of
guides in crankcase (1).
42 41 40 40 39 35 36
7. Remove the tension spring (42), support ring (41), v-sleeves
(40), pressure ring (39), from the seal sleeve (35). Examine
seals (36) carefully and replace if worn. Clean all parts.
7
LP121A-5100, LP200-5100, and LP250-5100 - Repair Instructions
38/38A
29B 29D 29C
8. Remove seal case (37)
from valve casing (43)
and inspect O-rings
(38/38A).
9. Check plunger surface (29B). If plunger pipe is worn, loosen tension screws (29C) and pull off plunger pipe to the
front. Clean front surface of plunger (25) thoroughly. Apply
a thin coat of Loctite to the tension screw threads (29C).
Note: Care must be taken that no glue gets between
the plunger pipe (29B) and the centering sleeve (29A).
Add new copper ring (29D).
10. Place new plunger pipe
(29B) carefully through
the oiled seals and push
seal sleeve (35) with
plunger pipe into the
crankcase guide. Note:
Make sure weep hole is
facing down.
11. Tighten the tension
screws (29C) to 310 in.lbs. (35NM).The plunger
pipe (29B) should not be
strained by over tightening of the tension screw
(29C) or through damage
to the front surface of the
plunger; otherwise, it will
probably break.
12. Place valve vasing
(43) over studs and
push rmly until seated
against the crankcase
(1). Tighten the hexagon
nuts (49A) in a crosswise
pattern (shown below) to
59 ft.-lbs. (80 NM)
6
412
8
7
3
5
8
LP121A-5100, LP200-5100, and LP250-5100 - Repair Instructions
To Dismantle Gear End
After removing valve casing (43) and plunger pipe (29B), drain oil. Remove crankcase cover (4)
and bearing cover (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 identication. 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 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 tting 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 22 ft.-lbs. (30 NM).
LP121A-5100, LP200-5100, and LP250-5100 Torque Specications
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
Pump System Malfunction
Preventative Maintenance Check List & Recommended Spare Parts List
CheckDailyWeekly50 hrs
Every
500 hrs
Every
1500 hrs
Every
3000 hrs
Oil Level/QualityX
Oil LeaksX
Water LeaksX
Belts, PulleyX
PlumbingX
Recommended Spare Parts
Oil Change (1 Quart) p/n 01153XX
Seal Spare Parts (1 kit/pump)
(see page 5 for kit list)
X
Oil Seal Kit (1 kit/pump)
(see page 5 for kit list)
X
Valve Spare Parts (1 kit/pump)
(see page 5 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
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
10
LP121A-5100, LP200-5100, and LP250-5100 Dimensions - mm (in)
11
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 discharge 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 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 modications made by the customer or third party.
6. The operation of pumps and or accessories exceeding the specications 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 WARRANTIES OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE AND ALL
SUCH WARRANTIES ARE HEREBY DISCLAIMED AND EXCLUDED BY THE MANUFACTURER.