Triplex Ceramic
Plunger Pump
Operating Instructions/
Repair and Service
Manual
Models
LP122A Series/LP123/LP255
For Models:
LP122A
LP122A-3100
LP122A-4000
LP123
LP255
Contents:
Installation Instructions: page 2
Pump Specifications:
Exploded View:
Parts List:
page 3-4
page 5
page 6
Kit List/Torque
Specifications:
page 7
Repair Instructions:
Dimensions:
pages 8-10
page 11
Warranty Information:
back page
Updated 5/01
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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
correctnozzlesizethatcorrespondswiththepump
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
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
39.4
*
*Intermittent duty only! - Consult factory!
3
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Specifications
Model LP255
Volume............................................................................................... Up to 26.0 GPM (147.6 l/m)
Discharge Pressure ............................................................................ Up to 2200*
Inlet Pressure ..................................................................................... Up to 90 PSI
Speed ................................................................................................. Up to 1000 RPM
Plunger Diameter............................................................................... 32 mm
Stroke................................................................................................. 42 mm
Crankcase Oil Capacity ..................................................................... 116 fl.oz.
Temperature of Pumped Fluids ......................................................... Up to 160oF
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/LP255 ............................................................ 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
correctnozzlesizethatcorrespondswiththepump
GPM.
HP = (GPM X PSI) / 1440
LP255 PULLEY SELECTION AND HORSEPOWER REQUIREMENTS
PUMP
PULLEY PULLEY
MOTOR
RPM
GPM
1000 PSI 1500 PSI 2000 PSI 2200 PSI
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
640
750
805
865
920
1000
13
9.3
13.9
17.8
20.9
22.4
24.1
25.6
27.9
18.6
23.7
27.9
29.9
32.1
34.1
37.1
20.4
26.1
30.6
32.8
35.4
37.6
40.9
16.6
19.5
20.9
22.5
23.9
26
11.9
13.9
14.9
16.1
17.1
18.6
*Intermittent duty only! - Consult factory!
4
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Exploded View - LP122A Series/LP123/LP255
5
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LP122A SERIES/LP123/LP255 PARTS LIST
A = LP122A
B = LP123
C = LP122-4000
D = LP122A-3100
E = LP255
ITEM PART NO. DESCRIPTION
QTY.
ITEM PART NO. DESCRIPTION
QTY.
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
1
1
1
1
35B
36
13141
13415
13025
13416
O-Ring (E only)
3
3
3
2
Oil Filler Plug
Crankcase Cover
O-Ring
V-Sleeve, Weep (A-D)
V-Sleeve, Weep (E)
4
36
5
36A
36A
36A
37
Pressure Ring, Weep, (A, B, C) 3
6
Oil Sight Glass W/Gasket
Oil Dipstick
1
1
1
4
4
5
5
1
1
1
1
2
2
2
8
8
2
2
3
1
1
1
3
6
6
13416-0100 Pressure Ring, (D)
3
3
3
3
3
6
6
6
3
3
3
3
3
1
1
1
1
1
6
6
6
6
6
6
6
8
06700
06701
07744
Pressure Ring (E)
9
O-Ring
Screw, (A, B, C, E)
Screw, (D)
Support Disc (E only)
Pressure Ring, (A, B, C)
10
10
11
11
12
12
13
13
14
15
16
17
17
20
20A
20B
21
22
23
24
24A
24B
25
39
39
07744-0100 Pressure Ring, (D)
Spring Washer, (A, B, C)
Spring Washer, (D)
Oil Drain Plug, (A, B, C, E)
Oil Drain Plug, (D)
Gasket, (A, C)
39
13026
07745
13027
07746
Pressure Ring (E)
V-Sleeve (A, B, C, D)
V-Sleeve (E)
40
40
41
Support Ring, (A, B, C)
41
06621-0100 Support Ring, (D)
Gasket, (B, D, E)
Bearing Cover
41
06702
06589
Support Ring (E)
Plug, (D only)
42
Crankshaft Seal
O-Ring
42A
43
07204-0100 Steel Ring, (D only)
13343
06625
Valve Casing, (A)
Valve Casing, (B)
Hex Screw, (A, B, C, E)
HexScrew, (D)
43
43
13343-4000 Valve Casing, (C)
13343-3000 Valve Casing, (D)
Taper Roller Bearing
Fitting Disc, 0.1mm
Fitting Disc, 0.15mm
Shaft Protector
43
43
06703
07748
Valve Casing, (E)
Valve Seat, (A, B, C, E)
44
44
07748-0100 Valve Seat, (D)
Crankshaft
Key
44A
44A
45
07150
06620
07749
O-Ring, (A, B, C, E)
O-Ring, (D)
Connecting Rod Assy.
Hex Screw
Valve Plate, (A, B, C, E)
45
07749-0100 Valve Plate, (D)
Spring Washer
46
07750
07751
Valve Spring
Crosshead Plunger
Base Assy.
46A
Valve Assy. Complete, (A, B, C, E)
3
3
3
3
3
3
3
3
3
3
3
3
3
(#44, 44A, 45, 46, & 47)
6
28
13232
07735
07736
13022
07737
Crosshead Pin
46A
07751-0100 Valve Assmebly Complete (D)
(#44, 44A, 45, 46, & 47)
29A
29B
29B
29C
29C
29D
29D
29E
29E
30
Centering Sleeve
Plunger Pipe (A-D)
Plunger Pipe (E)
Plunger Bolt, (A, B, C, E)
6
6
6
6
6
6
6
8
8
8
1
1
1
1
1
1
1
1
1
1
1
1
47
07752
07753
06504
06089
12055
06577
07157
07158
07159
07423
Spring Retainer
Plug, (A)
48
48
Plug, (B, E)
Plug, (C, D)
O-Ring, (A, B, C, E)
O-Ring, (D)
Stud Bolt
07737-0100 Plunger Bolt, (D)
48
07755
Copper Gasket, (A, B, C, E)
48A
48A
49
07761-0100 Gasket for Bolt, (D)
06087
06618
07789
07779
06120
06118
07133
06116
06119
06117
13342
Spacer Pipe, (A, B, C, E)
Spacer Pipe, (D)
49A
49B
50
Nut
Flinger (A, B, C, D)
Flinger (E)
Washer
30
31
Plug, (A,B, E)
Seal Retainer, Complete, (A, C) 3
50
07423-0100 Plug, (C, D)
31A
31B
32
Oil Seal, (A, C)
3
3
3
3
3
3
3
3
3
3
50A
50A
52
07161
Gasket, (A, B,C, E)
Radial Shaft Seal, (B, D, E)
Oil Seal Retainer, (A, C)
O-Ring, (A, C)
07755-0100 Gasket, (D)
13020
06607
07756
06626
Disk for Crankshaft
32A
33
53
Hexagon Screw
Backup Seal, (A, C)
Seal Sleeve, (A, B, C)
54
Plug 1" NPT, (A, C)
Plug 1" NPT, (B, E)
35
54
35
13342-0100 Seal Sleeve, (D)
54
13321-0100 Plug 1" BSP, (D)
07757
06627
35
06699
07740
06619
Seal Sleeve (E)
O-Ring, (A, B, C, E)
O-Ring, (D)
55
Plug 1-1/2" NPT, (A, C)
Plug, 1-1/4" NPT, (B, E)
35A
35A
55
55
13322-0100 Plug, 1" BSP, (D)
NOTE: For LP122 pumps manufactured prior to 5/94, and needing weep seal replacement, change the pressure ring
(36) to the newer style (p/n 13416) and use the new style weep seal (p/n 13415) in your pumps.
6
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LP122A SERIES/LP123/LP255 PUMP REPAIR KITS
Plunger Packing Kit
Valve Assembly Kit
LP122A. LP123, LP122A-4000, LP255
#09136
# 09477 (LP122A, LP123, LP122A-4000)
(for pumps manufatured after 4/98)
Item Part # Description
Qty.
3
Item
46A
48A
Part # Description
Qty.
3
35A
36
07740 O-ring
07751 Valve Assembly, Complete
12055 O-Ring
13415 V-Sleeve, Weep
07745 V-Sleeve
3
3
40
6
Plunger Packing Kit
Valve Assembly Kit
LP122A-3100
# 09535 (LP255)
Item Part # Description
Qty.
3
#09305
35A
35B
36
07740 O-ring
Item
46A
48A
Part #
07751-0100 ValveAssembly Complete
06577 O-Ring
Description
Qty.
3
13141 O-Ring
3
3
13025 V-Sleeve weep
13027 V-Sleeve
3
40
6
LP122A SERIES/LP123/LP255 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.
26 ft.-lbs.
10
17
24A
29C
48
07737/07737-0100
07753/06504/06089
07158
Plug, Valve
Nut, Stud Bolt
160 ft.-lbs.
60 ft.-lbs.
49A
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
35B
39
40
40
41
37
(LP255 only)
(LP255 only)
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 and 35B in Lp255A only)
from the manifold and seal sleeve, respectively. For LP255
only, remove support ring (37). 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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oil.
7. For LP122A & LP122A-4000
pumps, oil seal replacement
can be accomplished by pull-
ing the retainer forward out of
the crankcase. The o-ring
around the outside of the re-
tainer should be replaced and
lubricated with a light film of
8. The back-up seal (33) can be
pried out of the back of the
retainer (32) with a small
screwdriver. To replace with
new seal, lubricate edges of
new seal, then squeeze out-
side edges of seal, forcing the
seal to collapse 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.
To replace oil seal, apply a
light 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 installed first and that the
seal sits squarely in the re-
tainer.
TO REASSEMBLE PROCEED AS FOLLOWS:
29E 29A
29B
29D
29C
10. For LP122A & LP122A-4000
pumps,generouslylubricatethe
inside of the oil seals (31A &
33) and o-ring (32A). Next,
placethesealretainer,complete
(31) over the steel plunger base
seat firmly into the crankcase.
Replace the flinger (30).
11. If previously disassembled thoroughly clean all exposed surfaces on the
spacer (29E) and all exposed threads on the plunger bolt (29C) and the
steel 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) using a new copper gasket (29D) and the cleaned
plunger bolt (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
(orequivalent)adhesivetothethreads. Threadintosteelplungerbaseand
tighten to 26 ft.-lbs. BE CERTAIN ALL PARTS ARE CENTERED
WITH THE BOLT!
9
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36A
36
35
35A 35B (LP255 only)
39
12. Lubricate weep seal (36). Place, weep seal (36), and pressure ring (36A)
into the seal sleeve (35). Assemble the o-ring (35A and 35B for LP255
only) onto seal sleeve and lubricate.
13. For LP255 pumps, insert sup-
port ring (37) into valve casing
(43).Placesupportring(41)and
v-sleeves (40) into valve
casing.
7
5
6
8
4
1
2
3
14. Press seal sleeve assembly into
against the crankcase.
15. Place entire manifold/seal
sleeve assembly over the studs
and push firmly until seated
the manifold and seat firmly.
Put the support ring (41) on
plunger with v-side facing the
manifold.
16. Tighten hex nuts (49A) in a
crosswise pattern (shown
above) to 60 ft.-lbs.
48A) and tighten to 160 ft.-lbs.
19. Fill crankcase with approxi-
mately 116 fluid ounces of Gi-
ant oil or equivalent SAE 90
industrial gear oil and check oil
level of the crankcase with the
dipstick. Proper level is center
of two lines. Reinstall your Gi-
ant LP pump into your system.
firmly into manifold.
17. Next, place valve assemblies 18. Replace plug with o-ring (48, &
(46A) into manifold after first
lubricatingtheo-ring(44A).Seat
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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11
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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 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.
Liabilityunderthiswarrantyisonallnon-wearpartsandlimitedtothereplacementorrepairofthoseproductsreturned
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 REPRESENTA-
TION, 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
Ó Copyright 2001 Giant Industries, Inc.
05/01 LP122A/LP123/LP255.PM6
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