Giant MP Series, MP4126, MP4124, MP4120, MP4130HK Operating Instructions/ Repair And Service Manual
...
MP
Series
Triplex Ceramic Plunger Pump
Operating Instructions/
Repair and Service Manual
Pump Models:
MP4120
MP4124
MP4126
MP4130
MP4130HK
MP4135
Updated 01/18
Contents:
Installation Instructions: page 2
Preventive Maintenance
and Recommended
Spare Parts List: page 2
Pump Specications: page 3
Exploded View: page 4
Parts List: page 5
Repair Kits: page 6
Torque Specications: page 6
Repair Instructions: page 7
Dimensions: back page
Warranty Information: back page
INSTALLATION INSTRUCTIONS
Required NPSH refers to water: Specic
weight 1kg/dm3, viscosity 1 °E at max. permissible revolutions.
Operation and Maintenance
Check oil level prior to starting and ensure
trouble-free water supply.
Oil: Use 33.8 . ounces (1.0 liters) of Giant’s
part number 01154 or ISO VG 220 GL4 (e.g.
Aral Degol BG220) or SAE 90 GL4 gear oil.
Initial change after 50 operating hours and
then every 500 hours, after 6 months operation in any case.
Caution when operating in damp places or
with high temperature uctuations. Oil must
be changed immediately, should condensate
(frothy oil) occur in the gear box.
Keep NPSH under control.
Max. input pressure 145 PSI (10 bar), max.
suction head -4.35 (-0.3 bar).
Pressure in discharge line and in pump must
be at zero before any maintenance to the
pump takes place. Close up suction line. Disconnect fuses to ensure that the driving motor
does not get switched on accidentally.
Make sure that all parts on the pressure side of
the unit are vented and relled, with pressure
at zero, before starting the pump.
In order to prevent air, or an air/water-mixture
being absorbed and to prevent cavitation oc-
curring, the pump-NPSHR, positive suction
head and water temperature must be kept
under control.
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 plunger pumps are suitable for pumping clean water and other non-aggressive or
abrasive media with a specic weight similar to
water.
Safety Rules
Before pumping other liquids - especially
inammable, explosive and toxic media
Pump operation without safety valve as well
as any excess in the 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
- 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.
not be exceeded by more than 10%.
When the pump is in operation, the open
shaft end must be covered up by shaft pro-
tector (21), the driven shaft side and coupling
by a contact protector.
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 6 for kit lit)
Valve Spare Parts (1 kit/pump)
(See page 6 for kit list)
X
2
MP SERIES - PUMP SPECIFICATIONS
U.S. Measurements
Max.
Flow
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
MP4135 13.5 1885 1100 18.2 160 1.1 29.5
MP4130 15.4 1600* 1100 17.6 160 1.18 29.5
MP4130HK 15.4 1600 1100 17.6 195 1.18 N/A
MP4126 17.9 1600 1100 20.4 160 1.18 N/A
Metric Measurements
Max.
Flow
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
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
MP4126 67.7 11 0 1100 15.2 70 30 N/A
Max. Pres-
sure
Max. Pres-
sure
Max.
Speed
Max.
Speed
Power
Required
Power
Required
Max.
Temperature
Max.
Temperature
Plunger
Diameter
*Intermittent rating of 2000 PSI
Plunger
Diameter
*Intermittent rating of 140 bar
NPSH Re-
quired
NPSH Re-
quired
Consult the factory for special requirements that must be met if the
pump is to operate beyond one or more of the limits specied above.
Horsepower Ratings:
We recommend a 1.15 service factor be specied 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
Common Specications:
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)
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
Stroke (MP4126 only) ............ 1.18” (30 mm)
Weight ...................................66 lbs (30 kg)
Shaft Rotation............Top of Pulley Toward Fluid End
3
Exploded View - MP Series
4
MP SERIES PARTS LIST AND REPAIR KITS
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 Fitting Disc 2
20B 06962 Fitting Disc 2
21 05375 Shaft Protector 1
22 07251 Crankshaft (except MP4126) 1
22 04149 Crankshaft (MP4126 only) 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
( M P 4 1 2 6 / M P 4 1 3 0 / M P 4 1 3 0 H K ) 3
29B 13005 Ceramic Plunger, 28mm
(MP4135) 3
29C 13007 Tension Screw 3
29D 07258 Seal Washer 3
30 06136 Flinger 3
31 07260 Crankcase Oil Seal 3
35A 07263 Support Ring (MP4120) 3
35A 06079 Support Ring (MP4124) 3
35A 07273 Support Ring (MP4126/MP4130) 3
35A 06652 Support Ring (MP4135) 3
35B 06064 V-Sleeve (MP4120) 3
35B 06080 V-Sleeve (MP4124) 3
35B 07272 V-Sleeve (MP4126/MP4130) 3
35B 06137 V-Sleeve (MP4130HK) 3
35B 05687 V-Sleeve (MP4135) 3
35C 07265 Pressure Ring (MP4120) 3
35C 06081 Pressure Ring (MP4124) 3
35C 07271 Pressure Ring (MP4126/MP4130) 3
35C 13013 Pressure Ring (MP4135) 3
35D 07266 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 (MP4126/MP4130) 6
39 13013 Pressure Ring (MP4135) 6
ITEM PART# DESCRIPTION QTY.
40 07322 V-Sleeve (MP4120) 3
40 06083 V-Sleeve (MP4124) 3
40 07272 V-Sleeve (MP4126/MP4130) 3
40 05687 V-Sleeve (MP4135) 3
40 06137 V-Sleeve (MP4130HK) 3
40A 07272 V-Sleeve (MP4130HK) 3
41 07270 Support Ring (MP4120) 3
41 06084 Support Ring (MP4124) 3
41 07273 Support Ring (MP4126/MP4130) 6
41 06652 Support Ring (MP4135) 6
41A 07329 Spacer Ring (MP4120/MP4124) 3
41A 07274 Spacer Ring
(MP4126/MP4130/MP4135) 3
42 07275 Tension Spring (MP4120/MP4124) 3
42 07353 Tension Spring
(MP4126/MP4130/MP4135) 3
42A 06102 Tension Plug (MP4120/MP4124) 3
42A 06103 Tension Plug
(MP4126/MP4130/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
(MP4120/MP4130/MP4135) 3
46A 07283 Inlet Valve Spring
(MP4124/MP4126) 3
47 07284 Spring Retainer, Discharge 3
48 06108 Plug, (MP4120/MP4124) 3
48 07356 Plug, Brass
(MP4126/MP4130/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 (MP4126/MP4130
/MP4135) 3
52A 07329 Spacer Ring
(MP4120/MP4124 only) 3
53 12057 O-Ring (MP4120/MP4124) 3
53 07332 O-Ring
(MP4126/MP4130/MP4135) 3
53A 12027 O-ring (MP4120/MP4124 only) 3
54 06115 Spring Retainer, Inlet 3
55 06626 Plug, NPT, 1” 1
56 04732 Plug, NPT, 3/4” 1
57 13020 Disc for Crankshaft 1
5
MP SERIES PARTS LIST AND REPAIR KITS
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
35B 07272 V-Sleeve 3
40 07272 V-Sleeve 3
42B 07354 O-Ring, Tension Plug 3
48A 07332 O-Ring, Plug 3
MP4135 # 09665
Item Part # Description Qty
35B 05687 V-Sleeve 3
40 05687 V-Sleeve 3
42B 07354 O-Ring, Tension Plug 3
48A 07332 O-Ring, Plug 3
MP4130HK # 09664
Item Part # Description Qty
35B 06137 V-Sleeve, High Temp 3
40 06137 V-Sleeve, High Temp 3
40A 07272 V-Sleeve 3
42B 07354 O-Ring, Tension Plug 3
48A 07332 O-Ring, Plug 3
Valve Repair Kits
MP4120 # 09802
Item Part # Description Qty
42B 07332 O-Ring Tension Plug 3
44 07280 Valve Seat 6
44A 07281 O-Ring, Valve-Seat 6
45 06791-0100 Valve Plate 6
46 07283 Valve Spring, Discharge 3
46A 06959 Valve Spring, Inlet 3
48A 07332 O-Ring, Tension Plug 3
53 12057 O-Ring 3
53A 12027 O-Ring 3
MP4124 # 09803
Item Part # Description Qty
42B 07332 O-Ring Tension Plug 3
44 07280 Valve Seat 6
44A 07281 O-Ring, Valve-Seat 6
45 06791-0100 Valve Plate 6
46 07283 Valve Spring, Discharge 3
46A 07283 Valve Spring, Inlet 3
48A 07332 O-Ring, Tension Plug 3
53 12057 O-Ring 3
53A 12027 O-Ring 3
MP4126/MP4135 # 09809
Item Part # Description Qty
42B 07354 O-Ring Tension Plug 3
44 07280 Valve Seat 6
44A 07281 O-Ring, Valve-Seat 6
45 06791-0100 Valve Plate 6
46 07283 Valve Spring, Discharge 3
46A 07283 Valve Spring, Inlet 3
48A 07332 O-Ring, Tension Plug 3
53 07332 O-Ring 3
MP4130/MP4130HK # 09810
Item Part # Description Qty
42B 07354 O-Ring Tension Plug 3
44 07280 Valve Seat 6
44A 07281 O-Ring, Valve-Seat 6
45 06791-0100 Valve Plate 6
46 07283 Valve Spring, Discharge 3
46A 06959 Valve Spring, Inlet 3
48A 07332 O-Ring, Tension Plug 3
53 07332 O-Ring 3
Position Item# Description Torque Amount
1 06100 Crankcase Loctite 270 N/A
10 01010 Screw, Crankcase Cover N/A 221 in.-lbs. (25 Nm)
12 07109 Oil Drain Plug 30 ft.-lbs. (40 Nm)
17 07114 Hex Screw, Bearing Cover 221 in.-lbs. (25 Nm)
24 07253 Hex Screw, Connecting Rod 106 in.-lbs. (12 Nm)
29C 13007 Bolt, Plunger Loctite 243 247 in.-lbs. (28 Nm)
31 07260 Crankcase Oil Seal Loctite 403 N/A
42A 06102/06103 Plug, Inlet 107 ft.-lbs. (145 Nm)
48 06108/07356 Plug, Discharge 107 ft.-lbs. (145 Nm)
50 07158 Nut, Manifold Stud 59 ft.-lbs. (80 Nm)
MP SERIES TORQUE SPECIFICATIONS
6
To Check Valves
Suction Valve: Remove plugs (42A). Take out spacer pipe (51) and suction valve adaptor (52). For MP4120 and
MP4124 pumps, remove spacer ring (52A) as well. 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 and 53A for MP4120/MP4124 only). Replace as
necessary.
Discharge Valve: Remove 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 and 40A), grease new seals with special grease from pump manufacturer before
installing.
Check O-rings (42B, 44A, 53, 53A) and replace as necessary.
REPAIR INSTRUCTION - MP SERIES
Check rear v-sleeve (35 and 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 247 in.-lbs. (28 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 - MP4120/MP4124 only), 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).
To Dismantle Gear
Drain oil after dismantling the valve casing (43) and plunger pipes, then remove crankcase cover (4) and bearing
cover (14).
Loosen connecting rod screws (24) and push stem of connecting rod halves as far as possible into the crosshead
guides.
Important! Connecting rods are marked for identication. Do not twist connecting rod halves. Connecting 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 connecting rod shanks. Check shaft and connecting 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.
Remove 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
connecting rod screws (24) to 106 in.-lbs. (12 Nm).
7
MP SERIES DIMENSIONS - Inches (mm)
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 manufac-
turer’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 prod-
ucts 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 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 WARRANTIES 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., Toledo, Ohio 43607
PHONE (419) 531-4600, FAX (419) 531-6836, www.giantpumps.com
© Copyright 2018 Giant Industries, Inc.
05/18 MP Series.indd
Loading...