Model
LP122A-3100
Triplex Ceramic
Plunger Pump
Operating Instructions/
Repair and Service
Manual
Updated 11/06
Contents:
Installation Instructions: page 2
Pump Specifications: page 3
Exploded View: page 4
Parts List/Kits: page 5
Repair Instructions: pages 6-8
Trouble Shooting: page 9
Recommended Spare
Parts List: page 10
Torque Specifications: page 10
Pump Mounting
Selection Guide: page 10
Dimensions: page 11
Warranty Information: back 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 1600 F, it is important to
insure a positive head to the pump to prevent
cavitation.
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 valve 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 shutoff gun.
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 potential 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 80-90W Industrial Gear Lube Oil (p/n
01154)
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
2
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
T emperature of Pumped Fluids.........................................160
Inlet Port ..................................................................................................... 1-1/2" BSP
Discharge Port............................................................................................ 1" BSP
Crankshaft Mounting .................................................................................. Either Side
Shaft Rotation ................................................................... T op 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
o
F ............... 71oC
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.
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.
Pump speeds of 640 RPM and above require a minimum inlet pressure of 12 psig.
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:
HORSEPOWER INFORMATION
HP = (GPM X PSI) / 1440
LP122A-3100 PULLEY SELECTION AND HORSEPOWER REQUIREMENTS
PUMP
PULLEY
12.75" 3.95" 22.3 500 9.6 12.7 15.9 20.7 31.9
12.75" 4.35" 24.7 555 10.6 14.1 17.6 22.9 35.3
12.75" 4.95" 28.5 640 12.2 16.3 20.4 26.5 40.7
12.75" 5.35" 30.9 695 13.2 17.7 22.1 28.7 44.1
12.75" 5.75" 33.4 750 14.3 19.1 23.9 31.0 47.7
12.75" 6.15" 35.6 800 15.3 20.3 25.4 33.1 50.9
MOTOR
PULLEY
GPM RPM 600 PSI 800 PSI 1000 PSI 1300 PSI 2000 PSI*
3
Exploded View - LP122A-3100
4
SPARE PARTS LIST - LP122A-3100 PUMP
ITEM PART NO. DESCRIPTION QTY.
1 07759 Crankcase 1
2 13000 Oil Filler Plug 1
4 06085 Crankcase Cover 1
5 07104 O-Ring 1
6 07186 Oil Sight Glass W/Gasket 1
8 06086 Oil Dipstick 1
9 01009 O-Ring 1
10 01010-0400 Screw 4
11 08094 Spring Washer 5
12 07109-0400 Oil Drain Plug 1
13 07182 Gasket 1
14 07111 Bearing Cover 2
15 07112 Crankshaft Seal 2
16 07113 O-Ring 2
17 07114-0100 HexScrew 8
20 07116 Taper Roller Bearing 2
20A 07117 Fitting Disc, 0.1mm 1-3
20B 13001 Fitting Disc, 0.15mm 1-3
21 07118 Shaft Protector 1
22 13242 Crankshaft 1
23 13243 Key 1
24 13340 Connecting Rod Assy. 3
25 13341 Crosshead Plunger Base Assy. 3
28 13232 Crosshead Pin 3
29A 07735 Centering Sleeve 3
29B 07736 Plunger Pipe 3
29C 07737-0100 Plunger Bolt 3
29D 07161A-0100 Gasket for Bolt 3
ITEM PART NO. DESCRIPTION QTY.
29E 06618 Spacer Pipe 3
30 07779 Flinger 3
31 07133 Radial Shaft Seal 3
35 13342-0100 Seal Sleeve 3
35A 06619 O-Ring 3
36 13415 Grooved Ring 3
36A 13416A-0100 Pressure Ring 3
36B 06174 Drip Shield 3
39 07744-0100 Pressure Ring 3
40 07745 Sleeve 6
41 07746-0100 Support Ring 3
43 13018-3000 Valve Casing 1
44 07748-0300 Valve Seat 6
44A 06620 O-Ring 6
45 07749-0300 Valve Plate 6
46 07750 Valve Spring 6
46A 07751-0100 Valve Assy. Complete 6
47 07752 Spring Tension Cap 6
48 06089 Plug 6
48A 06577 O-Ring 6
49 07157 Stud Bolt 8
49A 07158 Nut 8
49B 07159 Washer 8
50 07423-0100 Plug 1
50A 07755-0100 Gasket 1
52 13020 Disk for Crankshaft 1
53 06607 Hexagon Screw 1
54 13321-0300 Plug 1" BSP 1
55 13322-0300 Plug, 1" BSP 1
LP122A-3100 Repair Kits
Plunger Kit
# 09575
Item Qty. Part# Description
35A 3 06619 O-Ring
36 3 13145 Grooved Ring
39 3 07744-0100 Pressure Ring
40 6 07745 Sleeve
Oil Seal Kit
# 09577
Item Qty. Part# Description
31 3 07133 Radial Shaft Seal
Valve Assembly Kit
#09576
Item Qty. Part # Description
44 6 07748-0300 Valve Seat
44A 6 06620 O-Ring
45 6 07749-0300 Valve Plate
46 6 07750 Valve Spring
47 6 07752 Spring Tension Cap
48A 6 06736 O-Ring
5
LP122A-3100 - Repair Instructions
44A 44 45 48 47
1. With a 30mm wrench, remove 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 threading 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.
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.
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 carefully and replace if worn. Clean all parts.
6
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
back of the pump.
LP122A-3100 - Repair Instructions
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:
new copper gasket (29) when repairing the plunger assembly.
Always use a
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 lubricated with a light film of oil.
29E 29A 29B 29D 29C
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
(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!
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.
7
10. Place support ring (41) and
v-sleeves (40) into valve
casing.
LP122A-3100 - Repair Instructions
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
sleeve assembly over the studs
and push firmly until seated
against the crankcase.
6
4 2
1
8
13. Tighten hex nuts (49A) in a
crosswise pattern (shown
above) to 60 ft.-lbs.
16. Fill crankcase with approximately 116 fluid ounces of Giant 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 Giant LP pump into your system.
7
3
5
14. Next, place valve assemblies
(46A) into manifold after first
lubricating the o-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
PUMP SYSTEM MALFUNCTION
MALFUNCTION CAUSE REMEDY
The Pressure and/ Worn packing seals Replace packing seals
or the Delivery Broken valve spring Replace spring
Drops Belt slippage Tighten or Replace belt
Water in crankcase High humidity Reduce oil change interval
Noisy Operation Worn bearings Replace bearings, Refill crankcase
Rough/Pulsating Worn packing Replace packing
Operation with Inlet restriction Check system for stoppage, air
Pressure Drop leaks, correctly sized inlet
Worn or Damaged nozzle Replace nozzle
Fouled discharge valve Clean valve assembly
Fouled inlet strainer Clean strainer
Worn or Damaged hose Repair/Replace hose
Worn or Plugged relief valve on pump Clean, Reset, and Replace worn parts
Cavitation Check suction lines on inlet of
pump for restrictions
Unloader Check for proper operation
Worn seals Replace seals
oil with recommended lubricant
Cavitation Check inlet lines for restrictions
and/or proper sizing
plumbing to pump
Accumulator pressure Recharge/Replace accumulator
Unloader Check for proper operation
Cavitation Check inlet lines for restrictions
and/or proper size
Pump Pressure as Restricted discharge plumbing Re-size discharge plumbing to Flow
Rated, Pressure Rate of Pump
Drop at Gun
Excessive Worn plungers Replace plungers
Leakage Worn packing/seals Adjust or Replace packing seals
Excessive vacuum Reduce suction vacuum
Cracked plungers Replace plungers
Inlet pressure too high Reduce inlet pressure
High Crankcase Wrong Grade of oil Giant oil is recommended
Temperature Improper amount of oil in crankcase Adjust oil level to proper amount
9
Preventative Maintenance Check-List & Recommended Spare Parts List
Check Daily Weekly 50hrs Every Every Every
500 hrs 1500 hrs 3000 hrs
Oil Level/Quality X
Oil Leaks X
Water Leaks X
Belts, Pulley X
Plumbing X
Recommended Spare Parts
Oil Change p/n 1154 X X
Seal Spare Parts (1 kit/pump) X
(See page 5 for kit list)
Oil Seal Kit (1 kit/pump) X
(See page 5 for kit lit)
Valve Spare Parts (1 kit/pump) X
(See page 5 for kit list)
LP122A-3100 TORQUE SPECIFICATIONS
Position Item# Description Torque Amount
10 08093 Screw, Cover 125 in.-lbs.
17 08095 Hex Screw, Bearing Cover 125 in.-lbs.
24A 13277 Hex Screw, Connecting Rod 250 in.-lbs.
29C 07131-0100 Plunger Bolt 26 ft.-lbs.
48 06077-0100 Plug, Valve 160 ft.-lbs.
49A 07158 Nut, Stud Bolt 60 ft.-lbs.
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
LP122A-3100 DIMENSIONS - INCHES (mm)
11
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.
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
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 REPRESENTATION, 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
prior to the
Copyright 2006 Giant Industries, Inc.
11/06 LP122A-3100.PMD
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