Giant LP122A-3100 User's Manual
Contents
1. UD LS LP122A SERIES LP123 LP255 PUMP REPAIR KITS Plunger Packing Kit 09477 LP122A LP123 LP122A 4000 for pumps manufatured after 4 98 Item Part Description 35A 07740 O ring 36 13415 V Sleeve Weep 40 07745 V Sleeve Plunger Packing Kit 09535 LP255 Item Part Description 35A 07740 O ring 35B 13141 O Ring 36 13025 V Sleeve weep 40 13027 V Sleeve Qty 3 3 6 ON Valve Assembly Kit 09136 Item Part 46A 07751 48A 12055 LP122A LP123 LP122A 4000 LP255 Description Valve Assembly Complete O Ring Valve Assembly Kit LP122A 3100 09305 Item Part Description 46A 07751 0100 Valve Assembly Complete ASA 06577 O Ring LP122A SERIES LP123 LP255 TORQUE SPECIFICATIONS Position Item 10 01010 08093 17 07114 08095 24A 13277 29C 07737 07737 0100 48 07753 06504 06089 49A 07158 Description Screw Cover Hex Screw Bearing Cover Hex Screw Connecting Rod Plunger Bolt Plug Valve Nut Stud Bolt Torque Amount 125 in lbs 125 in lbs 250 in lbs 26 ft 1bs 160 ft lbs 60 ft lbs Qty 3 3 Qty 3 3 LP122A Series LP123 Repair Instructions 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 out2. Models Updated 5 01 Contents Triplex Ceramic Plunger Pump Operating Instructions Repair and Service Manual LP122A Series LP123 LP255 For Models LP122A LP122A 3100 LP122A 4000 LP123 LP255 Installation Instructions page 2 Pump Specifications page 3 4 Exploded View page 5 Parts List page 6 Kit List Torque Specifications page Repair Instructions pages 8 10 Dimensions page 11 Warranty Information Dack page INSTALLATION INSTRUCTIONS 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 160 F it is important to insure a positive head to the pump to prevent cavitation See NPSH curve 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 v
3. 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 amp 46A into manifold after first lubricating the o 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 12 J 340 Discharge Ports Key Atx8x50 HA 2 7 NPT hal J io Centering DS M amp DIN 332 Intel Ports 2 1 1 2 NPT Discharge Ports 2x1 NPT Key Aldxax5d DIN 6885 Blatt 1 6 64 36 Centerin IS M8 DIN 33 Inlet Ports zy 1 1 2 NPT 1 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 o
4. 116 lbs NIS EE 35 mm Valve Casing LP122A dE Aluminum Bronze Valve C sme LP eco aar Ene an ERTE nEri Brass Valve Casing LUI220 400000 NIRNRNROIRIOIO YY 1TTTT 303 S S Valve Casing LP122A 3100 EKKENY YY Aluminum Bronze Nickle Volumetric Efficiency 800 RDM 0 96 Mechanical Efficiency 800 ER ees 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 whens 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 HP GPM X PSI 1440 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 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 GPM eeng GE RPM 600PSI 800 PSI 1000 PSI 1300 PSI 2000 PSI 22 3 12 75 3 95 500 96 127 159 207 319 24 7 12 75 28 5 12 75 3 30 9 33 4 35 6 39 4 Intermittent
5. Plug A B C E Oil Drain Plug D Gasket A C Gasket B D E Bearing Cover Crankshaft Seal O Ring Hex Screw A B C E HexScrew D Taper Roller Bearing Fitting Disc 0 1mm Fitting Disc 0 15mm Shaft Protector Crankshaft Key Connecting Rod Assy Hex Screw Spring Washer Crosshead Plunger Base Assy Crosshead Pin Centering Sleeve Plunger Pipe A D Plunger Pipe E Plunger Bolt A B C E Plunger Bolt D Copper Gasket A B C E Gasket for Bolt D Spacer Pipe A B C E Spacer Pipe D Flinger A B C D Flinger E Seal Retainer Complete A C Oil Seal A C Radial Shaft Seal B D E Oil Seal Retainer A C O Ring A C Backup Seal A C Seal Sleeve A B Seal Sleeve D Seal Sleeve E O Ring A B C E O Ring D C LP122 4000 ne LO Go GO GO GO LO GO Lo GO LO UO LO GO LO LS LO LD LO LO LO UD UD LO Ch Ch Lu rn RP RWNNOCOONNNE BPR be Li LN Es BRR RRR Re SS D LP122A 3100 ITEM PART NO 35B 36 36 36A 36A 13141 13415 13025 13416 13416 0100 06700 06701 07744 07744 0100 13026 07745 13027 07746 06621 0100 06702 06589 07204 0100 13343 06625 13343 4000 13343 3000 06703 07748 07748 0100 07150 06620 07749 07749 0100 07750 07751 07751 0100 07752 07753 06504 06089 12055 06577 07157 07158 07159 07423 07423 0100 07161 07755 0100 13020 06607 07756 06626 13321 0100 0
6. 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 If there are signs of oil leaking through the plunger oil seals then replacment is neccessary For LP122A amp LP122A 4000 remove the plunger pipe 29B before inspecting oil seals 31A amp 33 For the LP123 amp LP122A 3100 dissassemble the gear end and push out the seals from the back of the pump 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 Remove the seal sleeve 35 from the manifold and or crank case Remove the pressure rings 39 amp 36A v sleeves 40 amp 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 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 For LP122A amp LP122A 4000 pumps oil seal
7. duty only Consult factory Specifications Model LP255 ot Up to 26 0 GPM 147 6 Um Discharge Pressure i Up to 2200 Up to 90 PSI BIS Gl eebe Up to 1000 RPM EH 32 mm OR 42 mm Crankcase Oil UDG eege 116 fl oz Temperature of Pumped Fluids ERRSRSR ON 52 Up to 160 F IT OR e Gc 1 1 2 NPT Discharge TEE 1 NPT Crankshaft Mounting i Either Side Sa EE ee Top of Pulley Towards Fluid End ENEE LL 116 lbs Crank Pan MY E 35 mm Valve Casing LP122 EE Aluminum Bronze Valve Casme P12 LP 2 5 Soe onir neie Rea nEri Brass Valve Casing LP122A 4000 i 303 S S Valve Casing LP122A 3100 E Aluminum Bronze Nickle Volumetric Efficiency 800 RDM 0 96 Mechanical Efficiency 800 ER ees 0 85 PULLEY INEORMATION HORSEPOWER 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 We recommend that a 1 1 service factor be specified when s electing an electric motor as the power source To compute specific pump horsepower requirements use the following formula HP GPM X PSI 1440 LP255 PULLEY SELECTION AND HORSEPOWER REQUIREMENTS PUMP Bn RPM GPM
8. 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 amp 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 or equivalent adhesive to the threads Thread into steel plunger base and tighten to 26 ft lbs BE CERTAIN ALL PARTS ARE CENTERED WITH THE BOLT 12 Lubricate weep seal 36 Place weep seal 36 and pressure ring 36A 13 into the seal sleeve 35 Assemble the o ring 35A and 35B for LP255 only onto seal sleeve and lubricate For LP255 pumps insert sup port ring 37 into valve casing 43 Place support ring 41 and v sleeves 40 into valve casing 14 Press seal sleeve assembly into against the crankcase 15 Place entire manifold seal 16 the manifold and seat firmly Put the support ring 41 on plunger with v side facing the sleeve assembly over the studs and push firmly until seated Tighten hex nuts 49A in a crosswise pattern shown above to 60 ft Ibs manifold 48A and tighten to 160 ft Ibs 19 Fill crankcase with approxi mately
9. 1000 PSI 1500 PSI 2000 PSI PULLEY PULLEY 12 75 12 75 12 75 127 12 75 12 75 12 75 395 500 13 93 139 18 6 435 640 166 11 9 178 237 495 750 195 139 209 27 9 5 35 805 209 149 22 4 299 575 865 225 161 241 321 615 920 239 171 256 341 650 1000 26 186 27 9 37 1 Intermittent duty only Consult factory 2200 PSI 20 4 26 1 30 6 32 8 39 4 37 6 40 9 Exploded View LP122A Series LP123 LP2SS 000Y CCL Vd A ad vee 00LE VCZLd1 Cd Ba PART NO DESCRIPTION A LP122A ITEM l 07759 2 13000 4 06085 5 07104 6 07186 6 06086 9 01009 10 01010 10 08093 11 01011 11 08094 12 07109 12 12137 13 07110 E 07182 14 07111 15 07112 16 07113 17 07114 17 08095 20 07116 20A 07117 20B 13001 Sal 07118 22 13242 23 13243 24 13340 24A 13271 24B 13278 Ge 13341 26 13232 29A 07735 29B 07736 29B 13022 29C O31 29C 07737 0100 29D 07755 29D 07761 0100 Sib 06087 29B 06618 30 07789 30 07779 31 06120 31A 06118 31B 07133 32 06116 32A 06119 33 06117 35 13342 35 13342 0100 39 06699 35A 07740 35A 06619 LP122A SERIES LP123 LP255 PARTS LIST B LP123 Crankcase Oil Filler Plug Crankcase Cover O Rin 8 Oil Sight Glass W Gasket Oil Dipstick O Rin g Screw A B C E Screw D Spring Washer A B C Spring Washer D Oil Drain
10. 7757 06627 13322 0100 E LP255 DESCRIPTION O Ring E only V Sleeve Weep A D V Sleeve Weep E Pressure Ring Weep A B C Pressure Ring D Pressure Ring E Support Disc E only Pressure Ring A B C Pressure Ring D Pressure Ring E V Sleeve A B C D V Sleeve E Support Ring A B C Support Ring D Support Ring E Plug D only Steel Ring D only Valve Casing A Valve Casing B Valve Casing C Valve Casing D Valve Casing E Valve Seat A B C E Valve Seat D O Ring A B C E O Ring D Valve Plate A B C E Valve Plate D Valve Spring Valve Assy Complete A B C 44 44A 45 46 amp 47 Valve Assmebly Complete D 44 44A 45 46 amp 47 Spring Retainer Plug A Plug B E Plug C D O Ring A B C E O Ring D Stud Bolt Nut Washer Plug A B E Plug C D Gasket A B C E Gasket D Disk for Crankshaft Hexagon Screw Plug 1 NPT A C Plug 1 NPT B E Plug 1 BSP D Plug 1 1 2 NPT A C Plug 1 1 4 NPT B E 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 Q lt FH FH HH HO CO Ch Ch Ch Ch Ch OAD ON Fr ON ON ON ON ON ON CN ka DD WD WD WD DD CN WD lL LU LU
11. alve 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 He Sri teg 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 charts on pages 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 potentia
12. f 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 Normal wear and tear to standard wear parts Use of repair parts other than those manufactured or authorized by Giant Improper use of the product as a component part Changes or modifications made by the customer or third party The operation of pumps and or accessories exceeding the specifications set forth in the Operations Manuals provided by Giant Industries Inc SE tr SE SS SS 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 excl
13. l 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 90 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 f Specifications Models LP122A Series LP123 ot Up to 39 0 GPM 147 6 im Discharge Pressure i Up to 2000 PSI 138 Bar lee Up to 90 PSI 6 2 Bar EELER Up to 885 RPM Pl nger Diameter seeen 42 mm OE oe ee eee E E E E ee 42 mm Crankcase Oil Capatily eege 116 fl oz Temperature of Pumped Fluids ERRKRR ITO550 5 5 ou Up to 160 71 C IT OR Ga eee eer ee ee cc 1 1 2 NPT Discharge TEE 1 NPT Crankshaft Mounting i Either Side Sa ROLI Oses E en ee Top of Pulley Towards Fluid End ENEE eege
14. 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 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 TO REASSEMBLE PROCEED AS FOLLOWS 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 10 For LP122A amp LP122A 4000 pumps generously lubricate the inside of the oil seals 31A amp 33 and o ring 32A Next place the seal retainer 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
15. usive 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 ORIMPLIED INCLUDING WITHOUT LIMITATION ANY WARRANTIES OR MERCHANTABILITY OR FITNESS FORA 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 Copyright 2001 Giant Industries Inc 05 01 LP122A LP123 LP255 PM6
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