Giant Water Pump LP 122A User Manual

Triplex Ceramic  
Plunger Pump  
OperatingInstructions/  
Repair and Service  
Manual  
Models  
LP122A Series/LP123  
For Models  
LP122A  
LP122A-3100  
LP122A-4000  
LP123  
Contents:  
InstallationInstructions: page 2  
Pump Specifications:  
Exploded View:  
Parts List:  
page 3  
page 4  
page 5  
KitList/Torque  
Specifications:  
TroubleShooting:  
RepairInstructions:  
Dimensions:  
page 6  
page 7  
pages 8-10  
page 11  
back page  
Updated 6/00  
WarrantyInformation:  
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Specifications  
Models LP122A Series/LP123  
Volume ............................................................................................... Up to 39.0 GPM (147.6 l/m)  
Discharge Pressure ........................................................................... Up to 2000* PSI (138* Bar)  
Inlet Pressure..................................................................................... Up to 90 PSI (6.2 Bar)  
Speed ................................................................................................. Up to 885 RPM  
Plunger Diameter............................................................................... 42 mm  
Stroke................................................................................................. 42 mm  
Crankcase Oil Capacity ..................................................................... 116 fl.oz.  
Temperature of Pumped Fluids.......................................................... Up to 160oF (71oC)  
Inlet Port ............................................................................................ 1-1/2" NPT  
Discharge Port................................................................................... 1" NPT  
Crankshaft Mounting ......................................................................... Either Side  
Shaft Rotation .................................................................................... Top of Pulley Towards Fluid End  
Weight................................................................................................ 116 lbs.  
Crankshaft Diameter ......................................................................... 35 mm  
Valve Casing - LP122A ..................................................................... Aluminum Bronze  
Valve Casing - LP123 ........................................................................ Brass  
Valve Casing - LP122A-4000 ............................................................ 303 S.S.  
Valve Casing - LP122A-3100 ............................................................ Aluminum Bronze-Nickle  
Volumetric Efficiency @ 800 RPM ................................................... 0.96  
Mechanical Efficiency @ 800 RPM ................................................. 0.85  
PULLEY INFORMATION  
HORSEPOWER INFORMATION  
Pulley selection and pump speed are based on a 1725 We recommend that a 1.1 service factor be specified  
RPM motor and "B" section belts. When selecting when s electing an electric motor as the power source.  
desired GPM, allow for a ±5% tolerance on pumps To compute specific pump horsepower requirements,  
output due to variations in pulleys, belts and motors use the following formula:  
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 correspondswith the pump  
GPM.  
HP = (GPM X PSI) / 1440  
Pump speeds of 640 RPM and above require a minimum inlet pressure of 12 psig.  
Pump speeds of 805 RPM and above require a minimum inlet pressure of 14 psig.  
LP122A SERIES/LP123 PULLEY SELECTION AND HORSEPOWER  
REQUIREMENTS  
PUMP  
PULLEY PULLEY  
MOTOR  
GPM  
RPM  
600 PSI  
800 PSI 1000 PSI 1300 PSI 2000 PSI  
22.3  
24.7  
28.5  
30.9  
33.4  
35.6  
39.4  
12.75"  
12.75"  
12.75"  
12.75"  
12.75"  
12.75"  
12.75"  
3.95"  
4.35"  
4.95"  
5.35"  
5.75"  
6.15"  
6.50"  
500  
555  
640  
695  
750  
800  
885  
9.6  
12.7  
14.1  
16.3  
17.7  
19.1  
20.3  
22.5  
15.9  
17.6  
20.4  
22.1  
23.9  
25.4  
28.1  
20.7  
22.9  
26.5  
28.7  
31.0  
33.1  
36.6  
31.9  
35.3  
40.7  
44.1  
47.7  
50.9  
56.3  
10.6  
12.2  
13.2  
14.3  
15.3  
16.9  
*
*Intermittent duty only! - Consult factory!  
3
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Exploded View - LP122A Series/LP123  
*
*
4
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LP122A SERIES/LP123 PARTS LIST  
A = LP122A  
B = LP123  
C = LP122-4000  
D = LP122A-3100  
ITEM PARTNO. DESCRIPTION  
QTY.  
1
ITEM PARTNO. DESCRIPTION  
QTY.  
3
1
07759  
13000  
06085  
07104  
07186  
06086  
01009  
01010  
08093  
01011  
08094  
07109  
12137  
07110  
07182  
07111  
07112  
07113  
07114  
08095  
07116  
07117  
13001  
07118  
13242  
13243  
13340  
13277  
13278  
13341  
Crankcase  
35A  
35A  
36  
07740  
06619  
13415  
13416  
O-Ring,(A,B,C)  
2
OilFillerPlug  
1
O-Ring,(D)  
3
4
CrankcaseCover  
O-Ring  
1
V-Sleeve,Weep  
3
5
1
36A  
36A  
39  
PressureRing,Weep,(A,B,C)  
3
6
OilSightGlassW/Gasket  
OilDipstick  
O-Ring  
Screw, (A, B, C)  
Screw, (D)  
SpringWasher,(A,B,C)  
SpringWasher,(D)  
OilDrainPlug,(A,B,C)  
OilDrainPlug,(D)  
Gasket,(A,C)  
Gasket,(B,D)  
BearingCover  
CrankshaftSeal  
O-Ring  
1
13416-0100 PressureRing,(D)  
3
8
1
07744  
PressureRing,(A,B,C)  
3
9
1
39  
07744-0100 PressureRing,(D)  
3
10  
10  
11  
11  
12  
12  
13  
13  
14  
15  
16  
17  
17  
20  
20A  
20B  
21  
22  
23  
24  
24A  
24B  
25  
4
40  
07745  
07746  
V-Sleeve  
SupportRing,(A,B,C)  
6
4
41  
3
5
41  
06621-0100 SupportRing,(D)  
3
5
42  
06589  
Plug,(Donly)  
3
1
42A  
43  
07204-0100 SteelRing,(Donly)  
3
1
13343  
06625  
ValveCasing,(A)  
ValveCasing,(B)  
1
1
43  
1
1
43  
13343-4000 ValveCasing,(C)  
13343-3000 ValveCasing,(D)  
1
2
43  
1
2
44  
07748  
ValveSeat,(A,B,C)  
6
2
44  
07748-0100 ValveSeat,(D)  
6
Hex Screw, (A, B, C)  
HexScrew,(D)  
TaperRollerBearing  
FittingDisc,0.1mm  
FittingDisc,0.15mm  
ShaftProtector  
Crankshaft  
8
44A  
44A  
45  
07150  
06620  
07749  
O-Ring,(A,B,C)  
O-Ring,(D)  
ValvePlate,(A,B,C)  
6
8
6
2
6
2
45  
07749-0100 ValvePlate,(D)  
07750  
07751  
6
3
46  
ValveSpring  
ValveAssy.Complete,(A,B,C)  
(#44,44A,45,46,&47)  
6
1
46A  
1
6
Key  
1
46A  
07751-0100 ValveAssmeblyComplete(D)  
(#44,44A,45,46,&47)  
ConnectingRodAssy.  
HexScrew  
3
6
6
6
6
6
6
6
8
8
8
1
1
1
1
1
1
1
1
1
1
1
1
6
47  
07752  
07753  
06504  
06089  
06577  
12055  
07157  
07158  
07159  
07423  
SpringRetainer  
Plug,(A)  
Plug,(B)  
SpringWasher  
CrossheadPlunger  
BaseAssy.  
6
48  
48  
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
48  
Plug,(C,D)  
O-Ring,(A,B,C)  
O-Ring,(D)  
StudBolt  
28  
13232  
07735  
07736  
07737  
CrossheadPin  
CenteringSleeve  
PlungerPipe  
48A  
48A  
49  
29A  
29B  
29C  
29C  
29D  
29D  
29E  
29E  
30  
PlungerBolt,(A,B,C)  
49A  
49B  
50  
Nut  
07737-0100 PlungerBolt,(D)  
Washer  
07755  
CopperGasket,(A,B,C)  
Plug,(A,B)  
07761-0100 GasketforBolt,(D)  
50  
07423-0100 Plug,(C,D)  
06087  
06618  
07789  
06120  
06118  
07133  
06116  
06119  
06117  
13342  
SpacerPipe,(A,B,C)  
SpacerPipe,(D)  
Flinger  
SealRetainer,Complete,(A,C)  
OilSeal,(A,C)  
50A  
50A  
52  
07161  
Gasket,(A,B,C)  
07755-0100 Gasket,(D)  
13020  
13021  
07756  
06626  
DiskforCrankshaft  
31  
53  
HexagonScrew  
31A  
31B  
32  
54  
Plug1"NPT,(A,C)  
Plug1"NPT,(B)  
RadialShaftSeal,(B,D)  
OilSealRetainer,(A,C)  
O-Ring,(A,C)  
54  
54  
13321-0100 Plug1"BSP,(D)  
07757  
06627  
32A  
33  
55  
Plug1-1/2"NPT,(A,C)  
Plug,1-1/4"NPT,(B)  
BackupSeal,(A,C)  
SealSleeve, (A, B, C)  
55  
55  
35  
35  
13322-0100 Plug,1"BSP,(D)  
13342-0100 SealSleeve,(D)  
NOTE: For LP122 pumps manufactured prior to 1/1/94 used only one item #36 (part #07741, v-sleeve, weep). They  
also use one brass support ring (part #07743) with an o-ring (part #07758). When repairing this pump discard  
the brass support ring (part #07743) and the o-ring (part #07758). Replace with two (2) v-sleeves (part  
#07741), and one (1) o-ring (part #07653). The manufacturing date can be found on the side of the crankcase.  
5
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LP122A SERIES/LP123 PUMP REPAIR KITS  
Plunger Packing Kit  
Valve Assembly Kit  
LP122A. LP123, LP122A-4000  
#09136  
# 09135  
(for pumps manufatured before 4/98)  
Qty.  
3
Part # Description  
07740 O-ring  
Qty.  
Part # Description  
3
07751 ValveAssembly, Complete  
12055 O-Ring  
6
07741 V-Sleeve, Weep  
07745 V-Sleeve  
07653 O-Ring  
3
6
3
Plunger Packing Kit  
# 09477  
(for pumps manufatured after 3/98)  
Valve Assembly Kit  
LP122A-3100  
#09305  
Qty.  
3
Part # Description  
07740 O-ring  
Qty.  
Part #  
Description  
3
07751-0100  
06577  
ValveAssemblyComplete  
O-Ring  
3
13415 V-Sleeve, Weep  
07745 V-Sleeve  
3
6
LP122A SERIES/LP123 TORQUE SPECIFICATIONS  
Position  
Item#  
01010/08093  
07114/08095  
13277  
Description  
Screw, Cover  
Hex Screw, Bearing Cover  
Hex Screw, Connecting Rod  
Plunger Bolt  
Torque Amount  
125 in.-lbs.  
125 in.-lbs.  
250 in.-lbs.  
10  
17  
24A  
29C  
48  
07737/07737-0100  
07753/06504/06089  
07158  
26 ft.-lbs.  
160 ft.-lbs.  
60 ft.-lbs.  
Plug, Valve  
Nut, Stud Bolt  
49A  
6
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PUMPSYSTEMMALFUNCTION  
CAUSE  
REMEDY  
MALFUNCTION  
Wornpackingseals  
Brokenvalvespring  
Beltslippage  
WornorDamagednozzle  
Fouleddischargevalve  
Fouledinletstrainer  
WornorDamagedhose  
WornorPluggedreliefvalveonpump  
Cavitation  
Replacepackingseals  
Replacespring  
TightenorReplacebelt  
Replacenozzle  
Cleanvalveassembly  
Cleanstrainer  
Repair/Replacehose  
Clean,Reset,andReplacewornparts  
Checksuctionlinesoninletof  
pumpforrestrictions  
Checkforproperoperation  
ThePressureand/or  
theDeliveryDrops  
Unloader  
Highhumidity  
Wornseals  
Reduceoilchangeinterval  
Replaceseals  
Waterincrankcase  
NoisyOperation  
Wornbearings  
Cavitation  
Replacebearings,Refillcrankcase  
oilwithrecommendedlubricant  
Checkinletlinesforrestrictions  
and/orpropersizing  
Wornpacking  
Inletrestriction  
Replacepacking  
Rough/Pulsating  
Operationwith  
PressureDrop  
Checksystemforstoppage,air  
leaks,correctlysizedinletplumbing  
topump  
Accumulatorpressure  
Unloader  
Cavitation  
Recharge/Replaceaccumulator  
Checkforproperoperation  
Checkinletlinesforrestrictions  
and/orpropersize  
Restricteddischargeplumbing  
Re-sizedischargeplumbingto  
flowrateofpump  
PressureDropat  
Gun  
Wornplungers  
Replaceplungers  
ExcessiveLeakage  
Wornpacking/seals  
Excessivevacuum  
Crackedplungers  
Inletpressuretoohigh  
AdjustorReplacepackingseals  
Reducesuctionvacuum  
Replaceplungers  
Reduceinletpressure  
Wrong Grade of oil  
Improper amount of oil in crankcase  
Giant oil is recommended  
Adjust oil level to proper amount  
HighCrankcase  
Temperature  
7
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LP122A Series/LP123 - Repair Instructions  
44A  
44  
45  
48  
47  
1. With a 30mm wrench, re-  
move the six (6) plugs (48)  
from the valve casing (43).  
Inspect the o-rings (48A)  
and replace if necessary.  
Remove the complete valve  
assembly (46A) by thread-  
ing a 12mm bolt into the  
spring retainer and pulling  
straight out.  
2. To disassemble the valve, screw the bolt into the retainer until  
the valve plate (45) presses the valve seat (44) out of the spring  
retainer. Examine all parts and replace if necessary. If the seat  
doesn’t come out, use a valve puller to remove.  
36A  
36  
35  
35A  
39  
40  
40  
41  
4. Remove the seal sleeve (35) from the manifold and/or crank-  
case. Remove the pressure rings (39&36A), v-sleeves (40&36),  
support ring (41) and o-rings (35A) from the manifold and seal  
sleeve, respectively. Examine seals carefully and replace if  
worn. Clean all parts.  
3. Remove the eight (8) hex  
nuts (49A) with a 19mm  
wrench. Tap the back of  
the manifold (43) with a  
rubber mallet to dislodge  
and slide off the studs.  
5. If there are signs of oil  
leaking through the  
plunger oil seals, then  
replacment is  
neccessary.For  
LP122A &  
LP122A-4000, remove  
the plunger pipe (29B)  
before inspecting oil  
seals (31A & 33).  
For the LP123 &  
LP122A-3100  
dissassemble the gear  
end and push out the  
seals from the back of  
the pump.  
29E 29A  
29B  
29D  
29C  
6. Inspect surface of plunger pipe (29B) carefully. Remove any  
chemical or mineral deposits taking care not to damage the  
surface of the plunger. If plunger pipe is worn, remove the  
plunger bolt (29C) , plunger pipe (29B) and spacer (29E).  
Replace worn parts necessary. Note: Always use a new  
copper gasket (29) when repairing the plunger assembly.  
8
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7. For LP122A & LP122A-4000  
pumps, oilsealreplacementcan  
be accomplished by pulling the  
retainer forward out of the  
crankcase. The o-ring around  
the outside of the retainer  
should be replaced and lubri-  
cated with a light film of oil.  
8. The back-up seal (33) can be  
pried out of the back of the  
retainer(32)withasmallscrew-  
driver.Toreplacewithnewseal,  
lubricate edges of new seal,  
then squeeze outside edges of  
seal, forcing the seal to col-  
lapse into a figure 8. Tuck the  
two outside edges of the figure  
8 into the rear of the retainer,  
making sure that the inner lip of  
the seal faces the oil. The seal  
may now be pressed firmly into  
place.  
9. The front oil seal (31A) can  
now be removed by inserting a  
screwdriver through the rear  
of the retainer and tapping the  
seal out through the front of  
the retainer. Remove any ex-  
cess old loc-tite from retainer.  
Toreplaceoilseal, applyalight  
film of loc-tite around outside  
edges of seal. Tap seal firmly  
into the retainer with a wooden  
dowel making certain that the  
spring side of the seal is in-  
stalled first and that the seal  
sits squarely in the retainer.  
TOREASSEMBLEPROCEEDASFOLLOWS:  
29E 29A  
29B  
29D  
29C  
10. For LP122A & LP122A-4000  
pumps, generouslylubricatethe  
insideoftheoilseals(31A&33)  
and o-ring(32A).Next,placethe  
sealretainer,complete(31)over  
thesteelplungerbaseseatfirmly  
into the crankcase. Replace the  
flinger(30).  
11. If previously disassembled thoroughly clean all exposed surfaces on the  
spacer(29E)andallexposedthreadsontheplungerbolt(29C)andthesteel  
plunger base (25). Threads MUST be free of old loc-tite and any other  
material such as oil, grease, etc. This is necessary to ensure proper curing  
of new loc-tite. Giant recommends cleaning the threads with acetone or  
other suitable cleaner. Reassemble plunger assembly parts (29A, 29B, &  
29E)usinganewcoppergasket(29D)andthecleanedplungerbolt(29C).  
Slide the bolt through the center of the four (4) pieces so that the threaded  
end is exposed. Apply several drops of loc-tite 243 (or equivalent)  
adhesive to the threads. Thread into steel plunger base and tighten to 26  
ft.-lbs.BECERTAINALLPARTSARECENTEREDWITHTHEBOLT!  
9
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36A  
36  
35  
35A  
39  
12. Lubricateweepseal(36).Place,weepseal(36),andpressurering(36A)into  
the seal sleeve (35). Assemble the o-ring (35A) onto seal sleeve and  
lubricate.  
13. Place support ring (41) and  
v-sleeves (40) into valve  
casing(43).  
7
5
6
8
4
1
2
3
15. Placeentiremanifold/sealsleeve  
assembly over the studs and  
push firmly until seated against  
the crankcase.  
14. Press seal sleeve assembly into  
themanifoldandseatfirmly.Put  
the supportring(41)onplunger  
withv-sidefacingthemanifold.  
16. Tighten hex nuts (49A) in a  
crosswise pattern (shown  
above) to 60 ft.-lbs.  
19. Fillcrankcasewithapproximately  
116 fluid ounces of Giant oil or  
equivalentSAE90industrialgear  
oil and check oil level of the  
crankcase with the dipstick.  
Properleveliscenteroftwolines.  
Reinstall your Giant LP pump  
into your system.  
17. Next, place valve assemblies 18. Replace plug with o-ring (48, &  
(46A)intomanifoldafterfirstlu-  
bricating the o-ring (44A). Seat  
firmlyintomanifold.  
48A) and tighten to 160 ft.-lbs.  
Contact Giant Industries or your local distributor for maintenance  
of the gear end of your pump. Phone: 419/531-4600  
Contact Giant Industries for service school information. Phone: (419) 531-4600  
10  
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LP122A/LP122A-3100/LP123 DIMENSIONS (mm)  
LP122A-4000 DIMENSIONS (mm)  
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 self-service 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 dateof 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 requiredprior  
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  
INCIDENTALANDCONSEQUENTIALDAMAGESDIRECTLYORINDIRECTLYARISINGFROMTHESALEORUSE  
OF THIS PRODUCT.  
THELIMITEDWARRANTYSETFORTHHEREINISINLIEUOFALLOTHERWARRANTIESORREPRESENTATION,  
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 Avenue, P.O. Box 3187, Toledo, OH 43607  
PHONE: (419) 531-4600, FAX: (419) 531-6836, www.giantpumps.com  
Ó Copyright 2000 Giant Industries, Inc.  
6/00 LP122A/LP123.PM6  
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