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 installation. 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
1400 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 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.
4. Use of a dampener is necessary to minimize
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 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 designated 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 obtained 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 potential 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
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
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
specified when selecting an electric motor as
the power source. To compute specific pump
horsepower requirements, use the following
formula:
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
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)
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 orings (44A) if possible and
oil them before installing.
2) Remove the support ring
(44B), o-ring (44A) and tension spring (45).
5) Tighten up tension plugs
(48) to 107 ft.-lbs.
3) Take out discharge valve assemblies (46) by pulling
them upwards out of the
valve casing (43) with a
snap-ring tongs or any other
pull-off device. Then remove inlet valves in the
same way.
6
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.
3939A3738A 38
9) Check O-rings (39 & 38) and support rings (39A & 38A)
7) Remove the seal sleeve
(35) from the manifold
and /or crankcase.
on seal case (37).
8) Remove seal case (37) from
seal sleeve (35).
10) Remove leakage seal (36)
from the seal sleeve. If worn
or damaged replace with
new seal.
3540A40 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).
7
LP301A-5100 REPAIR INSTRUCTIONS
29B29D29C
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.
14) Place entire manifold/seal
sleeve assembly over the
studs and push firmly until
seated against the crankcase.
6
42
13
8
15) Tighten hex nuts (49A) in a
crosswise pattern (shown
above) to 59 ft.-lbs.
7
5
Weep Hole
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 disassemble the gear end (see
instructions below).
8
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).
Rough/PulsatingWorn packingReplace packing
Operation withInlet restrictionCheck system for stoppage, air
Pressure Dropleaks, correctly sized inlet
Worn or Damaged nozzleReplace nozzle
Fouled discharge valveClean valve assembly
Fouled inlet strainerClean strainer
Worn or Damaged hoseRepair/Replace hose
Worn or Plugged relief valve on pumpClean, Reset, and Replace worn parts
CavitationCheck suction lines on inlet of
pump for restrictions
UnloaderCheck for proper operation
Worn sealsReplace seals
oil with recommended lubricant
CavitationCheck inlet lines for restrictions
and/or proper sizing
plumbing to pump
Accumulator pressureRecharge/Replace accumulator
UnloaderCheck for proper operation
CavitationCheck inlet lines for restrictions
and/or proper size
Pump Pressure asRestricted discharge plumbingRe-size discharge plumbing to Drop at
gunflow rate of pump
Rated, Pressure
ExcessiveWorn plungersReplace plungers
LeakageWorn packing/sealsAdjust or Replace packing seals
High CrankcaseWrong Grade of oilGiant oil is recommended
TemperatureImproper amount of oil in crankcaseAdjust oil level to proper amount
Preventative Maintenance Check-List & Recommended Spare Parts List
CheckDailyWeekly50hrsEvery Every Every
500 hrs 1500 hrs 3000 hrs
Oil Level/QualityX
Oil LeaksX
Water LeaksX
Belts, PulleyX
PlumbingX
Recommended Spare Parts
Oil Change (1 Gallon) p/n 1154X X
Seal Spare Parts (1 kit/pump) X
Valve Spare Parts (1 kit/pump) X
10
LP301A-5100 DIMENSIONS - Inches (mm)
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 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 WARRANTIES OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE AND ALL SUCH
WARRANTIES ARE HEREBY DISCLAIMED AND EXCLUDED BY THE MANUFACTURER.