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
Ó Copyright 2000 Giant Industries, Inc.
6/00 LP122A/LP123.PM6
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