Triplex Ceramic
Plunger Pump
OperatingInstructions/
Repair and Service
Manual
Model
LP200, LP250 & LP250W-MT
Contents:
InstallationInstructions: page 2
LP200 Specifications:
Exploded View / Kits:
Parts List:
page 3
page 4
page 5
LP250/LP250W-MT
Specifications:
page 6
RepairInstructions:
page 7-9
TorqueSpecifications: page 9
PumpMountingSelection
Guide:
page9
TroubleShooting:
Recommended
Spare Parts List:
Dimensions:
page 10
Updated 5/02
page 10
page 11
back page
WarrantyInformation:
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Specifications
Model LP200
Volume ........................................................................................................ Up to19.0 GPM
Discharge Pressure .................................................................................... Up to 2900 PSI
Inlet Pressure.............................................................................................. Up to 90 PSI
Speed .......................................................................................................... Up to 1000 RPM
Plunger Diameter........................................................................................ 28 mm
Stroke.......................................................................................................... 42 mm
Crankcase Oil Capacity .............................................................................. 100 fl.oz.
Temperature of Pumped Fluids................................................................... Up to 140 oF
.................................................................................................................... 1600F up to 500 RPM
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 ......................................................................................................... 116 lbs.
Crankshaft Diameter .................................................................................. 35 mm
*Intermittentdutyforpumpspeedsinexcessof805RPM
PULLEY INFORMATION
Pulley selection and pump speed are based on
a1725RPMmotorand"B"sectionbelts. When
selecting desired GPM, allow for a ±5% toler-
ance on pumps output due to variations in
pulleys, belts and motors among manufactur-
ers.
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
1.SelectGPMrequired,thenselectappropriate
motor and pump pulley from the same line.
2.Thedesiredpressureisachievedbyselecting
the correct nozzle size that corresponds with
the pump GPM.
LP200 HORSEPOWER REQUIREMENTS
RPM GPM 1000 PSI 1500 PSI 2000 PSI 2900 PSI
500 9.5
640 12.2
750 14.3
805 15.3
865 16.5
920 17.5
1000 19.0
6.6
8.5
9.9
10.6
11.4
12.2
13.2
9.9
13.2
16.9
19.8
21.3
22.9
24.3
26.5
19.2
24.6
28.8
30.9
33.2
35.3
38.4
12.7
14.9
16.0
17.2
18.3
19.8
3
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Exploded View - LP200, LP250 & LP250W-MT
4
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LP200, LP250 & LP250W-MT PARTS LIST
ITEM PART
DESCRIPTION
Crankcase
QTY
1
1
1
1
1
1
1
1
4
5
1
1
2
2
2
8
ITEM PART
DESCRIPTION
GroovedRing(LP250)
LeakageSeal (LP250W-MT)
SealCase
O-Ring
O-Ring
PressureRing(LP200)
PressureRing
(LP250, LP250W-MT)
V-Sleeve(LP200)
V-Sleeve
(LP250, LP250W-MT)
Support Ring (LP200)
Support Ring
(LP250, LP250W-MT)
Sleeve Support (LP255)
Tension Spring
ValveCasing
QTY
1
2
4
5
6
7
8
9
07759
13000
06085
07104
07186
07187
06086
01009
01010
01011
07109
07182
07111
07112
07113
07114
07116
07117
13001
07118
13242
13243
13340
13227
13278
13341
13232
07125
13220
13022
36
36
37
38
38A
39
39
13360
13025
07170
07140
12055
13197
13026
3
3
3
3
3
3
Oil filler Plug Assy.
CrankcaseCover
O-ring, CrankcaseCover
Oil Sight Glass
Gasket for Sight Glass
Oil Dipstick Assy
O-Ring, Dipstick Assy.
CylinderScrew
Spring Ring
Plug
Gasket
BearingCover
RadialShaftSeal
O-Ring
HexagonScrew
TaperRollerBearing
Fitting Disc
Fitting Disc
Shaft Protector
Crankshaft
Woodruff Key
Connecting Rod Assy.
HexScrew
SpringWasher
Crosshead / Plunger Assy.
CrossheadPin
CenteringSleeve
Plunger Pipe (LP200)
Plunger Pipe
3
6
10
11
12
13
14
15
16
17
20
20A
20B
21
22
23
24
24A
24B
25
28
29A
29B
29B
40
40
13115
13027
6
3
41
41
13198
13028
3
3
3
1
9
41
42
43
44A
44B
06702
07173
13029
07150
06266
2
1-3
1-3
1
1
1
3
3
3
3
O-Ring
Support Ring for O-Ring
(LP250W-MT only)
Compression Spring
(LP250W-MT)
Valve Assembly
ValveSeat
ValvePlate
Valve Spring
Spacer Pipe
Plug
Plug (LP250W-MT)
Stud bolt
Hexagon Nut
Disc
Plug
3
45
06078
3
6
6
6
6
6
3
3
8
8
8
1
1
1
1
1
1
46
07060
07064
07063
07062
07066
07156
06077
07157
07158
07159
07423
07161
13020
13021
13321
13322
46A
46B
46C
46D
48
48
49
49A
49B
50
50A
52
3
3
3
(LP250, LP250W-MT)
TensionScrew
Copper Ring
Flinger
Oil Seal
SealSleeve(LP200)
SealSleeve
(LP250, LP250W-MT)
LeakageSeal(LP200)
3
3
3
3
3
3
29C
29D
30
31
35
07131
07755
07789
07133
13196
13024
Copper Ring
Disc for Crankshaft
HexagonScrew
Plug, 1”BSP
53
54
55
35
3
3
Plug1-1/2”BSP
36
13228
LP200, LP250 & LP250W-MT REPAIR KITS
Plunger Packing Kits
LP200
# 9307
LP250W-MT
# 9308-MT
Item Part # Description
Qty.
3
Item Part # Description
Qty.
36
38
13228 Leakage Seal
07140 O-Ring
36
38
13025 Leakage Seal
07140 O-Ring
3
3
3
38A 12055 O-Ring
40 13115 V-Sleeve
3
38A 12055 O-Ring
40 13027 V-Sleeve
3
6
6
Valve Kit
LP250, LP250W
# 9308
# 09196
Item Part # Description
Qty.
Item Part # Description
46A 07064 Valve Seat
46B 07063 Valve Plate
46C 07062 Valve Spring
Qty.
1
36
38
13360 Grooved Ring 3
07140 O-Ring
3
3
6
1
38A 12055 O-Ring
40 13027 V-Sleeve
1
5
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Specifications
Model LP250, LP250W-MT
Volume ........................................................................................................ Up to 26.0 GPM
Discharge Pressure .................................................................................... Up to 2200 PSI
Inlet Pressure.............................................................................................. Up to 90 PSI
Speed .......................................................................................................... Up to 1000 RPM
Plunger Diameter........................................................................................ 32 mm
Stroke.......................................................................................................... 42 mm
Crankcase Oil Capacity .............................................................................. 100 fl.oz.
Temperature of Pumped Fluids................................................................... Up to 140 oF
Inlet Port ..................................................................................................... 1-1/24" BSP
Discharge Port............................................................................................ 3 x 1" BSP
Crankshaft Mounting .................................................................................. Either Side
Shaft Rotation ................................................................................ Top of Pulley Towards Fluid End
Weight ......................................................................................................... 110 lbs.
Crankshaft Diameter .................................................................................. 35 mm
*Intermittentdutyforpumpspeedsinexcessof805RPM
PULLEY INFORMATION
Pulley selection and pump speed are based on
a1725RPMmotorand"B"sectionbelts. When
selecting desired GPM, allow for a ±5% toler-
ance on pumps output due to variations in
pulleys, belts and motors among manufactur-
ers.
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
1.SelectGPMrequired,thenselectappropriate
motor and pump pulley from the same line.
2.Thedesiredpressureisachievedbyselecting
the correct nozzle size that corresponds with
the pump GPM.
LP250 HORSEPOWER REQUIREMENTS
RPM GPM 1000 PSI 1500 PSI 2000 PSI 2200 PSI
500 13.0
640 16.6
750 19.5
805 20.9
865 22.5
920 23.9
1000 26.0
9.0
13.5
17.3
20.3
21.8
23.4
24.9
27.1
18.0
23.1
27.1
29.0
31.2
33.2
36.1
19.8
25.4
29.8
31.9
34.3
36.5
39.7
11.5
13.5
14.5
15.6
16.6
18.0
6
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LP200, LP250 & LP250W-MT - REPAIR INSTRUCTIONS
44A 44B
45
2. Remove the compression
spring (45) & o-rings (44A
& 44B-LP250W-MT only).
3. Remove the complete valve
assembly (46) with valve
pullers.
1. With a 30mm wrench,
remove the (3) plugs (48).
46A
46B
46D
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).
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) if possible and oil them before installing. Tighten up
tension plugs (48) to 107 ft.-lbs.
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.
6. Pull seal sleeves (35) out of
guides in crankcase (1).
7
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LP200, LP250 & LP250W-MT - REPAIR INSTRUCTIONS
38
29B
29D
29C
9. Check plunger surface (29B). If plunger pipe is worn out, 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).
8. Remove seal case (37) from
valve casing (43) and inspect
o-ring (38).
10. Place new plunger pipe
(29B) carefully through the
oiled seals and push seal
sleeve (35) with plunger
pipe into the crankcase
11. Tighten the tension screws
(29C) to 310 in.-lbs. 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 firmly
until seated against the
crankcase (1). Tighten the
hexagon nuts (49A) in a
crosswise pattern (shown
below) to 59 ft.-lbs.
guide. Note: Make sure
weep hole is facing down.
7
5
6
8
4
1
2
3
8
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To Dismantle Gear End
After removing valve casing (43) and plunger pipe (29B), drain oil. Remove gear 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 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 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 clear-
ance. Tighten connecting rod screws (24A) to 310 in.-lbs.
LP200, LP250 & LP250W-MT TORQUE SPECIFICATIONS
Position
Item#
13340
07131
07156
07158
Description
Torque Amount
24
29C
48
Inner Hex Screw, Connecting Rod
Tension Screw, Plunger
Plug, Discharge
310 in.-lbs.
310 in.-lbs.
107 ft.-lbs.
59 ft.-lbs.
49A
Hexagon Nut, Stud Bolts
Pump Mounting Selection Guide
Bushings
06496 - 35mm H Bushing
Pulley & Sheaves
07165 - 12.75” Cast Iron - 4 gr. - AB Section
Rails
07357 - Plated Steel Channel Rails
(L=11.75”xW1.88”xH=3.00”)
9
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PUMP SYSTEM MALFUNCTION
CAUSE
MALFUNCTION
REMEDY
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
The Pressure and/or
the Delivery Drops
Replace packing seals
Replace spring
Tighten or Replace belt
Replacenozzle
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
High humidity
Worn seals
Water in crankcase
Noisy Operation
Reduce oil change interval
Replace seals
Worn bearings
Cavitation
Replacebearings,Refillcrankcase
oilwithrecommendedlubricant
Check inlet lines for restrictions
and/or proper sizing
Worn packing
Inlet restriction
Rough/Pulsating
Operation with
Pressure Drop
Replacepacking
Check system for stoppage, air leaks,
correctly sized inlet plumbing to pump
Recharge/Replaceaccumulator
Check for proper operation
Check inlet lines for restrictions
and/or proper size
Accumulator pressure
Unloader
Cavitation
Re-size discharge plumbing to flowrate
of pump
Restricted discharge plumbing
Pressure Drop at Gun
ExcessiveLeakage
Worn plungers
Replace plungers
Worn packing/seals
Excessivevacuum
Cracked plungers
Inlet pressure too high
Adjust or Replace packing seals
Reduce suction vacuum
Replace plungers
Reduce inlet pressure
Wrong Grade of oil
Improper amount of oil in crankcase
High Crankcase
Temperature
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
Oil Seal Kit (1 kit/pump)
(See page 5 for kit lit)
X
X
X
Valve Spare Parts (1 kit/pump)
(See page 5 for kit list)
X
10
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LP200, LP250 & LP250W-MT DIMENSIONS
11
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GIANTINDUSTRIESLIMITEDWARRANTY
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
parts, used in portable pressure washers and in car wash applications, are
for five years from the date of shipment for all pumps used in NON-
clean
pump
warranted
SALINE,
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,EXPRESSORIMPLIED,INCLUDINGWITHOUTLIMITATIONANYWARRAN-
TIES 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
5/02LP200_250_250W_MT.PM6
Ó Copyright 2002 Giant Industries, Inc.
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