LP122A, LP123 and LP255 Pump Service Manual
Contents
1. 2000 PS eseigi 138 Bar Ia EE Upto 90 EE Up to 6 2 Bar Speed CONTINUOUS saeaasmactucasmmhadt lanas eT E nE E EEE ETRA Up to 800 RPM Speed Intermittent EE Up to 885 RPM Plunger Diameter oossasascuusasu eoru askuus a Run Redit 1 09 consessu dread 42 mm el TOO nm 42 mm Crankcase Oil Capacity Uu cn Eo 3 43 liters Temperature of Pumped Fluids Up to 160 F Up to 71 C Jua o T PT 2 x 1 1 2 NPT DISCAL ONS RTT 2x1 NPT Crankshaft Mounting E Either Side Shaft Rotation ccccceccsececcseseescesseesceeees Top of Pulley Towards Fluid End e EE Eeer 52 7 Kg Crankshaft Diameter a000nnnn00nnneneennnenenni E 35 mm Valve Casing OP KT T E Aluminum Bronze Valve Casing UD Brass Valve Casing LP122A 4000 WE 303 S S Volumetric Efficiency 800 APM swiss isicosssonccesiisveenasacevnteddevasnctasisenpaeads 0 96 Mechanical Efficiency S00 RN 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 Select2. 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 15 service factor be specified when s electing an electric motor as the power source To compute specific pump horse power requirements use the following formula HP GPM X PSI 1450 LP122A LP122A 4000 LP123 PULLEY SELECTION AND HORSEPOWER REQUIREMENTS PUMP MOTOR S GPM PULLEY PULLEY RPM 600 PSI 800 PSI 1000 PSI 1300 PSI 2000 PSI 223 12 75 3 95 500 96 127 159 207 319 Intermittent duty only Consult factory Exploded View LP122A LP122A 4000 LP123 LP255 LP255 Only LP255 Only LP122A LP122A 4000 LP123 LP255 PARTS LIST A LP122A B LP123 ITEM PARTNO l 07759 2 13000 4 06085 5 07104 6 07186 8 06086 9 01009 10 01010 1 01011 0400 12 7109 13 07182 14 07111 15 07112 l6 07113 17 07114 20 7116 20A 07117 20B 13001 2l 07118 22 13242 23 13243 24 13340 24A 13271 24B 13278 25 13341 28 13232 29A 07735 29B 07736 29B 13022 29C 07737 29D 07755 29E 06087 30 07789 3l 7133 39 13342 35 06699 35A 07740 NOTE DESCRIPTION Crankcase Oil Filler Plug Crankcase Cover O Ring Oil Sight Glass W Gasket Oil Dipstick O Ring Screw A B C E Spring Washer A B C Oil Drain Plug Gasket Bearing Cover Crankshaft Seal O
3. that high pressure operation in a pump system has many advantages But if itis 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 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 90 Industrial gear oil Giant s 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 Models LP122A LP122A 4000 LP123 JEE Metric Volume CGontmuous soaannnnnennneeneennnenenni 35A OPM EN 134 I m Volume Intermittent 4O OPN E 151 4 I m Discharge Pressure Continuous 1300 PSl 90 Bar Discharge Pressure Intermittent
4. ALE OR USE OF THIS PRODUCT THE LIMITED WARRANTY SET FORTH HEREIN IS IN LIEU OF ALL OTHER WARRANTIES OR REPRESENTA TION 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 O Copyright 2006 Giant Industries Inc 12 06 LP122A LP123 LP255 PMD
5. Ge 2 x 1 1 2 NPT IS CMG Co We OLS NN TO TE 2x1 NPT Crankshaft Mounting WE Either Side SMa PO le eener E toetetitoeecs Top of Pulley Towards Fluid End Weight e T ind M 52 7 Kg Crankshaft Diameter Er 35 mm Ic RI NER UU TU Brass Volumetric Efficiency 800 RPM RE 0 96 Mechanical Efficiency 800 HM 0 85 PULLEY INFORMATION HORSEPOWER INFORMATION Pulley selection and pump speed are based on a 1725 We recommend that a 1 15 service factor be RPM motor and B section belts When selecting specified when s electing an electric motor as the desired GPM allow for a 5 tolerance on pumps power source To compute specific pump horse output due to variations in pulleys belts and motors power requirements use the following formula among manufacturers l 2 Select GPM required then select appropriate HP GPM X PSI 1450 motor and pump pulley from the same line The desired pressure is achieved by selecting the correct nozzle size that corresponds with the pump GPM LP255 PULLEY SELECTION AND HORSEPOWER REQUIREMENTS PUMP MOTOR PULLEY PULLEY RPM 1000 PSI 1500 PSI 2000 PSI 2175 PSI 1275 3 95 500 13 90 135 181 196 MALFUNCTION The Pressure and or the Delivery Drops Water in crankcase Noisy Operation Rough Pulsating Operation with Pressure Drop Pump Pressure as Rated Pressure Drop at Gun Excessive Leakage High Crank
6. Ring Hex Screw Taper Roller Bearing Fitting Disc 0 1mm Fitting Disc 0 15mm Shaft Protector Crankshaft Key Connecting Rod Assy Hex Screw Spring Washer Crosshead Plunger Base Assy Crosshead Pin Centering Sleeve Plunger Pipe A C Plunger Pipe E Plunger Bolt Copper Gasket Spacer Pipe Flinger Radial Shaft Seal Seal Sleeve A B C Seal Sleeve E O Ring QTY Oo GW G2 O2 O2 Lu LO Go O29 O2 Ud Ld O2 ON ON G2 OD F2 F2 O0 NN ND ka Un JS ke ka Fa i Ech C LP122 4000 ITEM PARTNO 35B 13141 36 13415 36 13025 36A 13416A 36A 06700 3 06701 39 07744 39 13026 40 07745 40 13027 4 07746 4 06702 43 13343 43 06625 43 13343 4000 43 06703 d 07748 44A 07150 45 07749 46 07750 46A 07751 47 07752 48 07753 48 06504 48 06089 48A 12055 49 07157 49A 07158 49B 07159 50 07423 50 7423 0100 50A 07161 32 13020 53 06607 M4 07756 M4 06626 55 07757 55 06627 E LP255 DESCRIPTION O Ring Eonly V Sleeve Weep A C V Sleeve Weep E Pressure Ring Weep A B C Pressure Ring E Support Disc E only Pressure Ring A B C Pressure Ring E V Sleeve A B C D V Sleeve E Support Ring A B C Support Ring E ValveCasing A Valve Casing B Valve Casing C Valve Casing E Valve Seat O Ring Valve Plate Valve Spring Valve Assy Complete 44 44A 45 46 amp 47 Spring Retainer Plug A Plug BE Plug C O Ring Stud Bolt Nut Washer Pl
7. THE BOLT 8 Lubricate weep seal 36 Place weep seal 36 and pressure ring 36A 9 For LP255 pumps insert sup into the seal sleeve 35 Assemble the o ring 35A and 35B for LP255 port ring 37 into valve casing only onto seal sleeve and lubricate 43 Place support ring 41 and v sleeves 40 into valve casing 10 Place entire manifold seal 11 Tighten hex nuts 49A in a sleeve assembly over the studs crosswise pattern shown above and push firmly until seated to 60 ft Ibs against the crankcase 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 13 Replace plug with o ring 48 amp 46A into manifold after first 48A and tighten to 160 ft Ibs lubricating the o ring 44A Seat firmly into manifold LP122A LP122A 4000 LP123 LP255 TORQUE SPECIFICATIONS Position ltem Description Torque Amount 10 01010 Screw Cover 125 in lbs 17 07114 Hex Screw Bearing Cover 125 in Ibs 24A 13277 Hex Screw Connecting Rod 250 1n Ibs 29C 07737 Plunger Bolt 26 ft Ibs 48 06504 06089 Plug Valve 160 ft Ibs 49A 07158 Nut Stud Bolt 60 ft Ibs Contact Giant Industries or your local distributor for mainte n
8. Triplex Ceramic Plunger Pump Operating Instructions Models Repair and Service Manual LP122A LP122A 4000 LP123 LP255 Contents Installation Instructions page 2 Pump Specifications LP122A LP122A 4000 page 3 Pump Specifications LP123 page 3 Exploded View page 4 Parts List Kits page 5 Pump Specifications LP255 page 6 Trobleshooting Guide page Suggested Maintenance Schedule page Repair Instructions Torque Specs pages 8 10 Dimensions page 11 Updated 12 06 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 maxi mum 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 160 F it is important to insure a positive head to the pump to prevent cavitation See NPSH curve for LP122A Series LP123 pumps 3 The discharge plumbing from the pump should be properly sized to the flow r
9. ace if worn Clean all parts 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 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 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 amp 29E using anew 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 Ibs BE CERTAIN ALL PARTS ARE CENTERED WITH
10. ance 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 2 0 520 5 123 14 345 Discharge Ports 2 x 1 NPT ey Abel 2 51 r4 4 2 51 100 Centering DS M8 DIN 332 a HI Inlet Ports 8 3 210 2 x 1 1 2 NPT LP122A 4000 Dimensions mm 20 2 513 4 8 123 13 4 340 SE Ports EN Alyx dx50 24 19 ee Gei Kei 2 2 1 56 I p e N Rocce M 7 is d ch Zi 100 Wal ee B p ED D Centering 6 3 160 1 6 415 Pe 9 4 240 LERI Inlet Ports 8 0 204 8 3 210 2 x 1 1 2 NPT 15 2 385 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 accessor
11. ate 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 shut off gun HPSH t haad 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 Dampen ers 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 and 6 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 Cavita tion 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 LP122A LP123 NPSHR Curve Finally remember
12. case Temperature PUMP SYSTEM MALFUNCTION CAUSE Worn packing seals Broken valve spring Belt slippage 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 High humidity Worn seals Worn bearings oil with Cavitation Worn packing Inlet restriction Accumulator pressure Unloader Cavitation Restricted discharge plumbing Worn plungers Worn packing seals Excessive vacuum Cracked plungers Inlet pressure too high Wrong Grade of oil Improper amount of oil in crankcase REMEDY 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 Check for proper operation Reduce oil change interval Replace seals Replace bearings Refill crankcase recommended lubricant Check inlet lines for restrictions and or proper sizing Replace packing Check system for stoppage air leaks correctly sized inlet plumbing to pump Recharge Replace accumulator Check for proper operation Check inlet lines for restrictions and or proper size Re size discharge plumbing to Flow Rate of Pump Replace plungers Adjust or Replace packing seals Reduce suction vacuum Replace plungers Reduce inlet pressure Giant oil is recommended Adjust oil level to proper amou
13. ies 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 Normal wear and tear to standard wear parts Use of repair parts other than those manufactured or authorized by Giant Improper use of the product as a component part Changes or modifications made by the customer or third party p ur S DO I The operation of pumps and or accessories exceeding the specifications set forth in the Operations Manuals provided by Giant Industries Inc Liability underthis 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 INCIDENTAL AND CONSEQUENTIAL DAMAGES DIRECTLY OR INDIRECTLY ARISING FROM THE S
14. nt Preventative Maintenance Check List amp Recommended Spare Parts List Check Daily W eekly 50hrs Every 500 hrs 1500 hrs 3000 hrs Oil Level Quality Oil Leaks Water Leaks Belts Pulley Plumbing Recommended Spare Parts Oil Change 1 Gallon p n 1 E D a E E Seal Spare Parts 1 kit oump See page 5 for kit list Oil Seal Kit 1 kit pump See page 5 for Kt ist RII 1 See page 5 for kit list LP122A LP122A 4000 LP123 LP255 Repair Instructions 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 Remove the complete valve assembly 46A by threading a 12mm bolt into the spring retainer and pulling straight out 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 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 seal sleeve 35 from the manifold and or crankcase Remove the pressure rings 39 amp 36A v sleeves 40 amp 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 repl
15. ug A B E Plug C Gasket Disk for Crankshaft Hexagon Screw Plug I NPT A C Plug I NPT B E Plug 1 1 2 NPT A C Plug 1 1 4 NPT B E 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 Valve Assembly Kit 09136 Plunger Packing 09477 LP122A LP123 LP122A 4000 for pumps manufatured after 4 98 Kit Item Part Description Qty 35A 07740 O ring 3 36 13415 V Sleeve Weep 3 40 07745 V Sleeve 6 Plunger Packing Kit 09535 LP255 Item Part Description Qty 35A 07740 O ring 3 35B 13141 O Ring 3 36 13025 V Sleeve weep j 40 13027 V Sleeve 6 Item Part 46A 07751 Description Valve Assembly Complete 48A 12055 O Ring Q I ee eee bech Fe D I COO CO ON ON ON ON ON ON Eeer Oty 3 3 Specifications Model LP255 JE Metric tel n wzicienatncdawenpnceeencendesesniesesttyeatateiaancoeenss 26 0 GPM 98 l min Discharge Pressure esses 21439 Tl sentientes 150 Bar Inlet Pressure oues eret bibetuivlo baec Up to 90 PSI siscutrsirsbens Up to 6 2 Bar l9 e E EER E E Up to 1000 RPM Plunger Diameter E 32 mm tel E e E 42 mm Crankcase Oil Capacity La di No EE 3 43 liters Temperature of Pumped Fluids UD tO 160 EE 70 C NEU
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