Triplex Ceramic
Plunger Pump
Operating Instructions/
Repair and Service
Manual
Model
LP122A-3100
Contents:
Installation Instructions: page 2
Pump Specifications:
Exploded View:
Parts List/Kits:
Repair Instructions:
Trouble Shooting:
Recommended Spare
Parts List:
page 3
page 4
page 5
pages 6-8
page 9
page 10
Torque Specifications: page 10
Pump Mounting
Selection Guide:
Dimensions:
WarrantyInformation:
page 10
page 11
back page
Updated 11/06
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Specifications
Model LP122A-3100
U.S. ................. Metric
Volume .............................................................................. 35.6 GPM ........ 134.7 l/m
Discharge Pressure .......................................................... 1300 PSI.......... 90 Bar
Inlet Pressure.................................................................... 90 PSI ............. 6.2 Bar
Speed .......................................................................................................... Up to 800 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......................................... 160oF ............... 71oC
Inlet Port ..................................................................................................... 1-1/2" BSP
Discharge Port ............................................................................................ 1" BSP
Crankshaft Mounting .................................................................................. Either Side
Shaft Rotation ................................................................... Top of Pulley Towards Fluid End
Weight ............................................................................... 116 lbs. ............ 52.6 kg
Crankshaft Diameter ........................................................ 1.38.................. 35 mm
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.
LP122A-3100 PULLEY SELECTION AND HORSEPOWER REQUIREMENTS
PUMP
PULLEY PULLEY
MOTOR
GPM
RPM
600 PSI
800 PSI 1000 PSI 1300 PSI 2000 PSI*
12.75"
12.75"
12.75"
12.75"
12.75"
12.75"
3.95"
4.35"
4.95"
5.35"
5.75"
6.15"
22.3
24.7
28.5
30.9
33.4
35.6
500
555
640
695
750
800
9.6
12.7
14.1
16.3
17.7
19.1
20.3
15.9
17.6
20.4
22.1
23.9
25.4
20.7
22.9
26.5
28.7
31.0
33.1
31.9
35.3
40.7
44.1
47.7
50.9
10.6
12.2
13.2
14.3
15.3
3
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Exploded View - LP122A-3100
4
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SPARE PARTS LIST - LP122A-3100 PUMP
ITEM PARTNO.
DESCRIPTION
Crankcase
OilFillerPlug
CrankcaseCover
O-Ring
OilSightGlassW/Gasket
OilDipstick
O-Ring
QTY.
1
1
1
1
1
1
1
4
5
1
1
2
2
2
8
2
ITEM PARTNO.
DESCRIPTION
SpacerPipe
Flinger
RadialShaftSeal
SealSleeve
O-Ring
GroovedRing
PressureRing
DripShield
PressureRing
Sleeve
SupportRing
ValveCasing
ValveSeat
O-Ring
ValvePlate
ValveSpring
ValveAssy.Complete
SpringTensionCap
Plug
O-Ring
StudBolt
Nut
Washer
QTY.
3
3
3
3
3
3
3
3
3
6
3
1
6
6
6
6
6
6
6
6
8
8
8
1
1
1
1
1
1
07759
29E
30
06618
07779
2
13000
4
06085
31
07133
5
07104
35
35A
36
13342-0100
06619
13415
6
07186
8
06086
9
01009
36A
36B
39
13416A-0100
06174
07744-0100
07745
10
11
12
13
14
15
16
17
20
20A
20B
21
22
23
24
25
28
29A
29B
29C
29D
01010-0400
08094
07109-0400
07182
07111
07112
07113
07114-0100
07116
07117
13001
07118
13242
13243
13340
13341
13232
07735
07736
Screw
SpringWasher
OilDrainPlug
Gasket
BearingCover
CrankshaftSeal
O-Ring
40
41
43
44
44A
45
07746-0100
13018-3000
07748-0300
06620
07749-0300
07750
HexScrew
TaperRollerBearing
FittingDisc,0.1mm
FittingDisc,0.15mm
ShaftProtector
Crankshaft
46
1-3
1-3
1
1
1
46A
47
07751-0100
07752
48
06089
48A
49
06577
07157
Key
ConnectingRodAssy.
CrossheadPlungerBaseAssy. 3
CrossheadPin
CenteringSleeve
PlungerPipe
3
49A
49B
50
50A
52
07158
07159
07423-0100
07755-0100
13020
3
3
3
3
3
Plug
Gasket
DiskforCrankshaft
HexagonScrew
Plug1"BSP
Plug,1"BSP
07737-0100
07161A-0100
PlungerBolt
GasketforBolt
53
06607
54
55
13321-0300
13322-0300
1
LP122A-3100 Repair Kits
Valve Assembly Kit
Plunger Kit
# 09575
#09576
Item
35A
36
Qty.
3
Part#
Description
Item
44
Qty.
Part #
Description
Valve Seat
O-Ring
Valve Plate
Valve Spring
Spring Tension Cap
O-Ring
06619
O-Ring
6
6
6
6
6
6
07748-0300
06620
3
13145
07744-0100
07745
Grooved Ring
Pressure Ring
Sleeve
44A
45
39
3
6
07749-0300
07750
40
46
47
07752
06736
48A
Oil Seal Kit
# 09577
Item
31
Qty.
3
Part#
07133
Description
Radial Shaft Seal
5
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LP122A-3100 - 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.
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) from the
manifold and seal sleeve, respectively. Examine seals care-
fully 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.
6
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LP122A-3100 - Repair Instructions
5. If there are signs of
oil leaking through
the plunger oil seals,
then replacment is
neccessary.Remove
the plunger pipe
(29B) before inspect
ing oil seals (31A &
33). Dissassemble the
gear end and push out
the seals from the
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.
back of the pump.
29E 29A
29B
29D
29C
7. Oil seal replacement can 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. 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. Lubricate weep seal (36). Place, weep seal (36), and pressure ring (36A)
into the seal sleeve (35). Assemble the o-ring (35A) onto seal sleeve and
lubricate.
10. Place support ring (41) and
v-sleeves (40) into valve
casing.
7
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LP122A-3100 - Repair Instructions
6
8
7
5
4
1
2
3
11. Press seal sleeve assembly into
the manifold and seat firmly.
Put the support ring (41) on
plunger with v-side facing the
manifold.
12. Place entire manifold/seal
13. Tighten hex nuts (49A) in a
crosswise pattern (shown
above) to 60 ft.-lbs.
sleeve assembly over the studs
and push firmly until seated
against the crankcase.
16. 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.
14. Next, place valve assemblies
(46A) into manifold after first
lubricatingtheo-ring(44A).Seat
firmly into manifold.
15. Replace plug with o-ring (48, &
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
8
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PUMP SYSTEM MALFUNCTION
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
Worn or Damaged nozzle
Fouled discharge valve
Fouled inlet strainer
Worn or Damaged hose
Worn or Plugged relief valve on pump
Cavitation
Clean valve assembly
Clean strainer
Repair/Replace hose
Clean, Reset, and Replace worn parts
Check suction lines on inlet of
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
Pressure Drop
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
9
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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 p/n 1154
X
X
Seal Spare Parts (1 kit/pump)
(See page 5 for kit list)
Oil Seal Kit (1 kit/pump)
X
X
(See page 5 for kit lit)
Valve Spare Parts (1 kit/pump)
(See page 5 for kit list)
X
LP122A-3100 TORQUE SPECIFICATIONS
Position
Item#
08093
08095
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
13277
07131-0100
06077-0100
07158
Plug, Valve
Nut, Stud Bolt
160 ft.-lbs.
60 ft.-lbs.
49A
Pump Mounting Selection Guide
Bushings
06496 - 35mm H Bushing
Pulley & Sheaves
07165 - 12.75” Cast Iron - 4 gr. - AB Section
Rails
07357 - Plated Steel Channel Rails
(L=11.75”xW1.88”xH=3.00”)
10
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LP122A-3100 DIMENSIONS - INCHES (mm)
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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, EXPRESSORIMPLIED, INCLUDINGWITHOUTLIMITATIONANYWARRANTIESORMERCHANTABILITY
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.
11/06 LP122A-3100.PMD
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