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:
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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
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Exploded View - LP122A/LP122A-4000/LP123/LP255
4
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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
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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
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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
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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
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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
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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
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LP122A/LP123/LP255 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 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
Copyright 2006 Giant Industries, Inc.
12/06 LP122A_LP123_LP255.PMD
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