Giant Coffeemaker LP122A User Manual

Triplex Ceramic  
Plunger Pump  
OperatingInstructions/  
Repair and Service Manual  
Models  
LP122A/LP122A-4000/LP123/LP255  
Contents:  
Installation Instructions:  
page 2  
Pump Specifications - LP122A/LP122A-4000 page 3  
Pump Specifications - LP123:  
Exploded View:  
page 3  
page 4  
Parts List/Kits:  
page 5  
Pump Specifications - LP255:  
Trobleshooting Guide:  
Suggested Maintenance Schedule:  
Repair Instructions/Torque Specs.:  
Dimensions:  
page 6  
page 7  
page 7  
pages 8-10  
page 11  
back page  
Updated 12/06  
WarrantyInformation:  
Specifications  
Models LP122A/LP122A-4000/LP123  
U.S. .....................................(Metric)  
Volume (Continuous) ........................................... 35.4 GPM ............................(134 l/m)  
Volume (Intermittent)........................................... 40 GPM ...............................(151.4 l/m)  
Discharge Pressure (Continuous) ........................ 1300 PSI ..............................(90 Bar)  
Discharge Pressure (Intermittent) ....................... 2000 PSI ..............................(138 Bar)  
Inlet Pressure....................................................... Up to 90 PSI .......................(Up to 6.2 Bar)  
Speed (Continuous)............................................................................................Up to 800 RPM*  
Speed (Intermittent) ...........................................................................................Up to 885 RPM**  
Plunger Diameter................................................. 1.65” ....................................(42 mm)  
Stroke................................................................... 1.65” ....................................(42 mm)  
Crankcase Oil Capacity ....................................... 116 fl.oz. ..............................(3.43 liters)  
Temperature of Pumped Fluids............................ Up to 160oF .........................(Up to 71oC)  
Inlet Ports ..........................................................................................................2 x 1-1/2" NPT  
Discharge Ports .................................................................................................2 x 1" NPT  
Crankshaft Mounting .........................................................................................Either Side  
Shaft Rotation ...................................................... Top of Pulley Towards Fluid End  
Weight .................................................................. 116 lbs. ................................(52.7 Kg)  
Crankshaft Diameter ........................................... 1.38” ....................................(35 mm)  
Valve Casing - LP122A .....................................................................................Aluminum Bronze  
Valve Casing - LP123 ........................................................................................Brass  
Valve Casing - LP122A-4000 ............................................................................303 S.S.  
Volumetric Efficiency @ 800 RPM ...................................................................0.96  
Mechanical Efficiency @ 800 RPM .................................................................0.85  
*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.  
PULLEY 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% toler-  
ance on pumps output due to variations in  
pulleys, belts and motors among manufactur-  
ers.  
1. Select GPM required, then select  
appropriatemotor 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.  
HORSEPOWER INFORMATION  
We recommend that a 1.1 service factor be speci-  
fied 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  
LP122A/LP122A-4000/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
Exploded View - LP122A/LP122A-4000/LP123/LP255  
4
LP122A/LP122A-4000/LP123/LP255 PARTS LIST  
A = LP122A B = LP123  
C = LP122-4000  
E = LP255  
ITEM PARTNO. DESCRIPTION  
QTY.  
1
ITEM PARTNO. DESCRIPTION  
QTY.  
3
1
07759  
13000  
06085  
07104  
07186  
06086  
01009  
01010  
Crankcase  
35B  
36  
13141  
13415  
13025  
13416A  
06700  
06701  
07744  
13026  
07745  
13027  
07746  
06702  
13343  
06625  
O-Ring(Eonly)  
2
OilFillerPlug  
CrankcaseCover  
O-Ring  
1
V-Sleeve,Weep(A-C)  
V-Sleeve,Weep(E)  
PressureRing,Weep,(A,B,C)  
PressureRing(E)  
3
4
1
36  
3
5
1
36A  
36A  
37  
3
6
OilSightGlassW/Gasket  
OilDipstick  
1
3
8
1
SupportDisc(Eonly)  
PressureRing,(A,B,C)  
PressureRing(E)  
3
9
O-Ring  
1
39  
3
10  
11  
12  
13  
14  
15  
16  
17  
20  
20A  
20B  
21  
22  
23  
24  
24A  
24B  
25  
Screw, (A, B, C, E)  
4
39  
6
01011-0400 SpringWasher,(A,B,C)  
5
40  
V-Sleeve(A,B,C,D)  
V-Sleeve(E)  
6
07109  
07182  
07111  
07112  
07113  
07114  
07116  
07117  
13001  
07118  
13242  
13243  
13340  
13277  
13278  
13341  
OilDrainPlug  
Gasket  
1
40  
6
1
41  
SupportRing,(A,B,C)  
SupportRing(E)  
3
BearingCover  
CrankshaftSeal  
O-Ring  
2
41  
3
2
43  
ValveCasing,(A)  
1
2
43  
ValveCasing,(B)  
1
HexScrew  
8
43  
13343-4000 ValveCasing,(C)  
1
TaperRollerBearing  
FittingDisc,0.1mm  
FittingDisc,0.15mm  
ShaftProtector  
Crankshaft  
2
43  
06703  
07748  
07150  
07749  
07750  
07751  
ValveCasing,(E)  
ValveSeat  
O-Ring  
1
2
44  
6
3
44A  
45  
6
1
ValvePlate  
ValveSpring  
ValveAssy.Complete  
(#44,44A,45,46,&47)  
SpringRetainer  
Plug,(A)  
6
1
46  
6
Key  
1
46A  
ConnectingRodAssy.  
HexScrew  
3
6
6
6
6
6
6
8
8
8
1
1
1
1
1
1
1
1
1
6
47  
07752  
07753  
06504  
06089  
12055  
07157  
07158  
07159  
07423  
SpringWasher  
CrossheadPlunger  
BaseAssy.  
6
48  
48  
Plug,(B,E)  
Plug,(C)  
3
3
3
3
3
3
3
3
3
3
3
3
3
48  
28  
13232  
07735  
07736  
13022  
07737  
07755  
06087  
07789  
07133  
13342  
06699  
07740  
CrossheadPin  
CenteringSleeve  
PlungerPipe(A-C)  
PlungerPipe(E)  
PlungerBolt  
48A  
49  
O-Ring  
29A  
29B  
29B  
29C  
29D  
29E  
30  
StudBolt  
49A  
49B  
50  
Nut  
Washer  
Plug,(A,B,E)  
CopperGasket  
SpacerPipe  
50  
07423-0100 Plug,(C)  
50A  
52  
07161  
13020  
06607  
07756  
06626  
07757  
06627  
Gasket  
DiskforCrankshaft  
HexagonScrew  
Flinger  
31  
RadialShaftSeal  
SealSleeve,(A,B,C)  
SealSleeve(E)  
O-Ring  
53  
35  
54  
Plug1"NPT,(A,C)  
Plug1"NPT,(B,E)  
Plug1-1/2"NPT,(A,C)  
Plug,1-1/4"NPT,(B,E)  
35  
54  
35A  
55  
55  
NOTE: For LP122 pumps manufactured prior to 5/94, which need 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.  
LP122A/LP122A-4000/LP123/LP255 PUMP REPAIR KITS  
Plunger Packing Kit  
Valve Assembly Kit - #09136  
# 09477 (LP122A, LP123, LP122A-4000)  
(for pumps manufatured after 4/98)  
Item  
46A  
48A  
Part # Description  
Qty.  
3
3
07751 Valve Assembly, Complete  
12055 O-Ring  
Item  
35A  
36  
Part #  
07740 O-ring  
13415 V-Sleeve, Weep  
07745 V-Sleeve  
Description  
Qty.  
3
3
6
40  
Plunger Packing Kit  
# 09535 (LP255)  
Item  
35A  
35B  
36  
Part #  
Description  
Qty.  
07740 O-ring  
13141 O-Ring  
13025 V-Sleeve weep  
13027 V-Sleeve  
3
3
3
6
40  
5
Specifications  
Model LP255  
U.S. .....................................(Metric)  
Volume ................................................................. 26.0 GPM ............................(98 l/min)  
Discharge Pressure ............................................. 2175 PSI ..............................150 Bar)  
Inlet Pressure....................................................... Up to 90 PSI .......................Up to 6.2 Bar)  
Speed .................................................................................................................Up to 1000 RPM  
Plunger Diameter................................................. 1.26” ....................................(32 mm)  
Stroke................................................................... 1.65” ....................................(42 mm)  
Crankcase Oil Capacity ....................................... 116 fl.oz. ..............................(3.43 liters)  
o
Temperature of Pumped Fluids............................ Up to 160oF .........................(70 C)  
Inlet Ports ..........................................................................................................2 x 1-1/2" NPT  
Discharge Ports .................................................................................................2 x 1" NPT  
Crankshaft Mounting .........................................................................................Either Side  
Shaft Rotation ...................................................... Top of Pulley Towards Fluid End  
Weight .................................................................. 116 lbs. ................................(52.7 Kg)  
Crankshaft Diameter ........................................... 1.38” ....................................(35 mm)  
Valve Casing ......................................................................................................Brass  
Volumetric Efficiency @ 800 RPM ...................................................................0.96  
Mechanical Efficiency @ 800 RPM .................................................................0.85  
HORSEPOWER INFORMATION  
We recommend that a 1.1 service factor be speci-  
fied when s electing an electric motor as the power  
source. To compute specific pump horsepower  
requirements, use the following formula:  
PULLEY 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.  
HP = (GPM X PSI) / 1440  
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.  
LP255 PULLEY SELECTION AND HORSEPOWER REQUIREMENTS  
PUMP  
PULLEY PULLEY  
MOTOR  
RPM  
GPM  
1000 PSI 1500 PSI 2000 PSI 2175 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  
9.0  
13.5  
17.3  
20.3  
21.8  
23.4  
24.9  
27.1  
18.1  
23.1  
27.1  
29.0  
31.3  
33.2  
36.1  
19.6  
25.1  
29.5  
31.6  
34.0  
36.1  
39.3  
16.6  
19.5  
20.9  
22.5  
23.9  
26  
11.5  
13.5  
14.5  
15.6  
16.6  
18.1  
6
PUMPSYSTEMMALFUNCTION  
MALFUNCTION  
CAUSE  
REMEDY  
The Pressure and/  
or the Delivery  
Drops  
Worn packing seals  
Broken valve spring  
Belt slippage  
Replace packing seals  
Replace spring  
Tighten or Replace belt  
Replace nozzle  
Clean valve assembly  
Clean strainer  
Repair/Replace hose  
Clean, Reset, and Replace worn parts  
Check suction lines on inlet of  
Worn or Damaged nozzle  
Fouled discharge valve  
Fouled inlet strainer  
Worn or Damaged hose  
Worn or Plugged relief valve on pump  
Cavitation  
pump for restrictions  
Unloader  
Check for proper operation  
Water in crankcase  
Noisy Operation  
High humidity  
Worn seals  
Reduce oil change interval  
Replace seals  
Worn bearings  
oil with  
Cavitation  
Replace bearings, Refill crankcase  
recommended lubricant  
Check inlet lines for restrictions  
and/or proper sizing  
Rough/Pulsating  
Operation with  
PressureDrop  
Worn packing  
Inlet restriction  
Replace packing  
Check system for stoppage, air  
leaks, correctly sized inlet  
plumbing to pump  
Accumulator pressure  
Unloader  
Cavitation  
Recharge/Replace accumulator  
Check for proper operation  
Check inlet lines for restrictions  
and/or proper size  
Pump Pressure as  
Rated, Pressure  
Drop at Gun  
Restricted discharge plumbing  
Re-size discharge plumbing to Flow  
Rate of Pump  
Excessive  
Leakage  
Worn plungers  
Replace plungers  
Worn packing/seals  
Excessive vacuum  
Cracked plungers  
Inlet pressure too high  
Adjust or Replace packing seals  
Reduce suction vacuum  
Replace plungers  
Reduce inlet pressure  
High Crankcase  
Temperature  
Wrong Grade of oil  
Improper amount of oil in crankcase  
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  
Seal Spare Parts (1 kit/pump)  
(See page 5 for kit list)  
X
X
X
X
Oil Seal Kit (1 kit/pump)  
(See page 5 for kit lit)  
Valve Spare Parts (1 kit/pump)  
(See page 5 for kit list)  
X
7
LP122A/LP122A-4000/LP123/LP255 - Repair Instructions  
44A  
44  
45  
48  
47  
1. With a 30mm wrench, re-  
move the six (6) plugs  
(48) from the valve cas-  
ing (43). Inspect the o-  
rings (48A) and replace if  
necessary.  
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 neces-  
sary. If the seat doesn’t come out, use a valve puller to  
remove.  
Remove the complete  
valve assembly (46A) by  
threading a 12mm bolt  
into the spring retainer and  
pulling straight out.  
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  
crankcase. 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, respec-  
tively. 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.  
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 assem-  
bly.  
8
LP122A/LP122A-4000/LP123/LP255 - Repair Instructions  
TO REASSEMBLE PROCEED AS FOLLOWS:  
29E 29A  
29B  
29D  
29C  
7. If previously disassembled thoroughly clean all exposed surfaces on the  
spacer (29E) and all exposed threads on the plunger bolt (29C) and the  
steelplungerbase(25).ThreadsMUSTbefreeofoldloc-titeandanyother  
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!  
36A  
36  
35  
35A 35B (LP255 only)  
39  
8. 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.  
9. For LP255 pumps, insert sup-  
port ring (37) into valve casing  
(43).Placesupportring(41)and  
v-sleeves (40) into valve  
casing.  
7
6
8
4
1
2
3
5
10. Place entire manifold/seal  
sleeve assembly over the studs  
and push firmly until seated  
against the crankcase.  
11. Tighten hex nuts (49A) in a  
crosswisepattern(shownabove)  
to 60 ft.-lbs.  
9
LP122A/LP122A-4000/LP123/LP255 - Repair Instructions  
14. 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.  
12. Next, place valve assemblies  
(46A) into manifold after first  
lubricatingtheo-ring(44A).Seat  
firmly into manifold.  
13. Replace plug with o-ring (48, &  
48A) and tighten to 160 ft.-lbs.  
LP122A/LP122A-4000/LP123/LP255 TORQUE SPECIFICATIONS  
Position  
Item#  
01010  
07114  
13277  
07737  
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  
06504/06089  
07158  
Plug, Valve  
Nut, Stud Bolt  
160 ft.-lbs.  
60 ft.-lbs.  
49A  
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  
LP122A/LP123/LP255 Dimensions (mm)  
LP122A-4000 Dimensions (mm)  
11  
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 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  
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  
Copyright 2006 Giant Industries, Inc.  
12/06 LP122A_LP123_LP255.PMD  

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