Giant LP121A-5100 User manual

Triplex Ceramic
Plunger Pump
Operating Instructions/
Repair and Service
Manual
Contents:
Installation Instructions: page 2
Pump Specifications: page 3
Exploded View: page 4
Parts List/Kits: page
Repair Instructions: pages 6-8
Trouble Shooting: page 9
Recommended Spare
Parts List/Pump
Mounting Selection
Guide/Torque
Specifications: page 10
Dimensions: page 11
Model
LP121A-5100
Updated 11/02

2
NOTE: Contact Giant Industries for Service School Infor ation. Phone: [phone]
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 installa-
tion. 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
1 00 F, it is important to insure a positive head
to the pump to prevent cavitation. See NPSH
curve.
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 shut-off gun.
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.
IMP RTANT PERATING C NDITI NS
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 Giant Recommended il
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.
4. Use of a dampener is necessary to minimize
pulsation at drive elements, plumbing, connec-
tions, 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 pulsa-
tion. 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 desig-
nated 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 ob-
tained from the charts on pages 3.
. 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.
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.

3
Specifications
Model LP121A-5100
Volume ............................................................................................... Up to 31.7 GPM (120 LPM)
Discharge Pressure ............................................................................ Up to 1740 PSI (120 Bar)
Inlet Pressure ..................................................................................... Up to 90 PSI ( .2 Bar)
Speed ................................................................................................. Up to 1000 RPM
Plunger Diameter ............................................................................... 3 mm
Stroke ................................................................................................. 42 mm
Crankcase Oil Capacity ..................................................................... 11 fl.oz. (3,430 ml)
Temperature of Pumped Fluids ......................................................... Up to 1 0oF (71oC)
Inlet Port ............................................................................................ 3 x 1-1/2" BSPP
Discharge Port ................................................................................... 3 x 1 BSPP
Crankshaft Mounting ......................................................................... Either Side
Shaft Rotation .................................................................................... Top of Pulley Towards Fluid End
Weight ................................................................................................ 11 lbs. (52. kg)
Crankshaft Diameter .......................................................................... 35 mm
Valve Casing ...................................................................................... 31 S.S.
Volumetric Efficiency @ 800 RPM................................................... 0.9
Mechanical Efficiency @ 800 RPM.................................................. 0.85
PULLEY INF RMATI N
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.
H RSEP WER INF RMATI N
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:
HP = (GPM X PSI) / 1440
Pump speeds of 40 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.
PUMP
PULLEY
MOTOR
PULLEY
GPM RPM 600 PSI 800 PSI 1000 PSI 1300 PSI 1740 PS
I
12.75"
3.95"
15.9
500
6.6
8.8
11.0
14.4
19.2
12.75"
4.35"
17.6
555
7.3
9.8
12.2
15.9
21.3
12.75"
4.95"
20.3
640
8.5
11.3
14.1
18.3
24.5
12.75"
5.35"
22.0
695
9.2
12.2
15.3
19.9
26.6
12.75"
5.75"
23.8
750
9.9
13.2
16.5
21.5
28.8
12.75"
6.15"
25.4
800
10.6
14.1
17.6
22.9
30.7
12.75"
6.50"
31.7
1000
13.2
17.6
22.0
28.6
38.3
LP121-5100 PULLEY SELECTION AND HORSEPOWER REQUIREMENTS

4
Exploded View - LP121A-5100

5
ITEM PART N . DESCRIPTI N QTY.
1 07759 Crankcase 1
2 13000 Oil Filler Plug 1
4 0 085 Crankcase Cover 1
5 07104 O-Ring 1
0718 Oil Sight Glass W/Gasket 1
8 0 08 Oil Dipstick 1
9 01009 O-Ring 1
10 08093 Screw 4
11 08094 Spring Washer 5
12 12137 Oil Drain Plug 1
13 07182 Gasket 1
14 07111 Bearing Cover 2
15 07112 Crankshaft Seal 2
1 07113 O-Ring 2
17 08095 HexScrew 8
20 0711 Taper Roller Bearing 2
20A 07117 Fitting Disc, 0.1mm 2
20B 13001 Fitting Disc, 0.15mm 3
21 07118 Shaft Protector 1
22 13242 Crankshaft 1
23 13243 Key 1
24 13340 Connecting Rod Assy. 3
24A 13277 Hex Screw
24B 13278 Spring Washer
25 13341 Crosshead Plunger Base Assy.3
28 13232 Crosshead Pin 3
29A 07125 Centering Sleeve 3
29B 07130 Plunger Pipe 3
29C 07131-0100 Plunger Bolt 3
29D 071 1-0100 Gasket for Bolt 3
ITEM PART N . DESCRIPTI N QTY.
30 07779 Flinger 3
31 07133 Radial Shaft Seal 3
35 07135-0100 Seal Sleeve 3
3 13291 Grooved Ring 3
37 07139-0100 Seal Case 3
38 07140 O-Ring 3
39 07142-0100 Pressure Ring 3
40 07144 Sleeve
41 0714 -0100 Support Ring 3
42 07147 Tension Spring 3
43 13018-5000 Valve Casing 1
44A 07150 O-Ring
44B 0 2 Support Ring
45 0 078 Compression Spring 3
4 070 0-0100 Valve Assembly
4 A 070 4-0100 Valve Seat
4 B 070 3-0100 Valve Plate
4 C 07750-0100 Valve Spring
4 D 070 Spacer Pipe
48 0 077-0100 Plug
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 0 07 Hexagon Screw 1
54 13321-0100 Plug 1" BSP 1
55 13322-0100 Plug, 1" BSP 1
SPARE PARTS LIST - LP121A-5100 PUMP
LP121A-5100 Repair Kits
Plunger & Oil Seal Kit
# 09523
Item Qty.Part Description
31 3 07133 Radial Shaft Seal
36 3 13291 Grooved Ring
38 6 07140 O-Ring
39 3 07142-0100 Pressure Ring
40 6 07144 Sleeve
Val e Assembly Kit
#09524
Item Qty.Part Description
46 6 07060-0100 Valve Assembly, Com-
plete
44A 9 07150 O-Ring
44B 3 06266 Support Ring

6
1. With a 30mm wrench, re-
move the six ( ) plugs (48)
from the valve casing (43).
Inspect the o-rings (48A)
and replace if necessary.
Remove the complete valve
assembly (4 A) 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.
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 crank-
case. Remove the pressure rings (39&3 A), v-sleeves (40&3 ),
support ring (41) and o-rings (35A and 35B in Lp255A only)
from the manifold and seal sleeve, respectively. For LP255
only, remove support ring (37). Examine seals carefully and
replace if worn. Clean all parts.
. 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.
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
36A 36 35 35A 35B 39 40 40 41 37
(LP255 only) (LP255 only)
44A 44 45 48 47

7
11. 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!
7. For LP122A & LP122A-4000
pumps, oil seal replacement
can be accomplished by pull-
ing the retainer forward out of
the crankcase. The o-ring
around the outside of the re-
tainer should be replaced and
lubricated with a light film of
oil.
10. For LP122A & LP122A-4000
pumps, generously lubricate the
inside of the oil seals (31A &
33) and o-ring (32A). Next,
place the seal retainer, complete
(31) over the steel plunger base
seat firmly into the crankcase.
Replace the flinger (30).
TO REASSEMBLE PROCEED AS FOLLOWS:
29E 29A 29B 29D 29C
8. The back-up seal (33) can be
pried out of the back of the
retainer (32) with a small
screwdriver. To replace with
new seal, lubricate edges of
new seal, then squeeze out-
side edges of seal, forcing the
seal to collapse 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.
To replace oil seal, apply a
light 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 installed first and that the
seal sits squarely in the re-
tainer.
LP122A Series/LP123/LP255 - Repair Instructions

8
12. 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.
14. Press seal sleeve assembly into
the manifold and seat firmly.
Put the support ring (41) on
plunger with v-side facing the
manifold.
15. Place entire manifold/seal
sleeve assembly over the studs
and push firmly until seated
against the crankcase.
18. Replace plug with o-ring (48, &
48A) and tighten to 160 ft.-lbs.
13. For LP255 pumps, insert sup-
port ring (37) into valve casing
(43). Place support ring (41) and
v-sleeves (40) into valve
casing.
17. Next, place valve assemblies
(46A) into manifold after first
lubricating the o-ring (44A). Seat
firmly into manifold.
16. Tighten hex nuts (49A) in a
crosswise pattern (shown
above) to 60 ft.-lbs.
19. 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.
Contact Giant Industries or your local distributor for maintenance
of the gear end of your pump. Phone: [phone]
Contact Giant Industries for service school information. Phone: [phone]
36A 36 35 35A 35B (LP255 only) 39
64 2 7
81 3
LP122A Series/LP123/LP255 - Repair Instructions

9
PUMP SYSTEM MALFUNCTION
MALFUNCTION
The Pressure and/
or the elivery
rops
Water in crankcase
Noisy Operation
Rough/Pulsating
Operation with
Pressure rop
Pressure rop at
Gun
Excessive Leakage
High Crankcase
Temperature
CAUSE
Worn packing seals
Broken valve spring
Belt slippage
Worn or amaged nozzle
Fouled discharge valve
Fouled inlet strainer
Worn or amaged hose
Worn or Plugged relief valve on pump
Cavitation
Unloader
High humidity
Worn seals
Worn bearings
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
REME Y
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
pump for restrictions
Check for proper operation
Reduce oil change interval
Replace seals
Replace bearings, Refill crankcase
oil with 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 amount

10
Preventative Maintenance Check-List & Reco ended 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 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)
Position Item# Description Torque mount
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.
LP121A-5100 TORQUE SPECIFICATIONS
Pump Mounting Selection Guide
Bushings
06496 - 3 mm H Bushing
Pulley & Sheaves
07165 - 12.7  Cast Iron - 4 gr.
AB Section
Rails
07357 - Plated Steel Channel Rails
(L=11.7 x W=1.88x H=3.00)

11
LP121 -5100 DIMENSIONS - INCHES (mm)

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. ur 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 N N-SALINE, clean water applications.
2. ne (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 N T 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 perations
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 [phone]
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 N T BE LIABLE F R FURTHER L SS, DAMAGES, R EXPENSES, INCLUDING
INCIDENTAL AND C NSEQUENTIAL DAMAGES DIRECTLY R INDIRECTLY ARISING FR M THE SALE R
USE F THIS PR DUCT.
THE LIMITED WARRANTY SET F RTH HEREIN IS IN LIEU F ALL THER WARRANTIES R REPRESENTA-
TI N, EXPRESS R IMPLIED, INCLUDING WITH UT LIMITATI N ANY WARRANTIES R MERCHANTABILITY
R FITNESS F R A PARTICULAR PURP SE 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 [phone], FAX [phone], www.giantpumps.com
Ó Copyright 2002 Giant Industries, Inc.
11/02 LP121A-5100.PM6