Giant LP122A-3100 User manual

Contents:
Installation Instructions: page 2
Pump Specications: 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 Specications: page 10
Pump Mounting Selection Guide: page 10
Dimensions: page 11
Warranty Information: back page
Triplex Ceramic
Plunger Pump
Operating Instructions/
Repair and Service Manual
Models
LP122A-3100 & LP250-3100
Updated 6/12

2
NOTE: Contact Giant Industries for Service School Information.
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 installation. If you have
unique requirements, please contact Giant
Industries, Inc. or your local distributor for as-
sistance.
1. The pump should be installed at 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
ow rate of the pump with no unnecessary restric-
tions that can cause cavitation. Teon tape should
be used to seal all joints. If pumps are to be oper-
ated at temperatures in excess of 160oF for the
LP122A-3100 pump or 86o F for the LP250-3100
pump, 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 ow 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 pres-
sure 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.
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 rst
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 pul-
sation 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 Indus-
tries, Inc. Required horsepower for system opera-
tion 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 recom-
mended 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 ow 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 uids 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
Pump speeds of 640 RPM and above require a minimum inlet pressure of 12 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% 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.
HORSEPOWER INFORMATION
We recommend that a 1.1 service factor be specied
whenselectinganelectricmotorasthepowersource.
To compute specic pump horsepower requirements,
use the following formula:
HP = (GPM X PSI) / 1440
RPM GPM 600 PSI 800 PSI 1000 PSI 1300 PSI
500 22.3 9.3 12.4 15.5 20.1
555 24.7 10.3 13.7 17.2 22.3
640 28.5 11.9 15.8 19.8 25.7
695 30.9 12.9 17.2 21.5 27.9
750 33.4 13.9 18.6 23.2 30.2
800 35.6 14.8 19.8 24.7 32.1
LP122A-3100 PULLEY SELECTION AND
HORSEPOWER REQUIREMENTS
LP122A-3100 Specications
U.S. Metric
Volume...........................................................................................35.6 GPM ............................................ 134.7 L/min
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 .oz....................................................3.43 liters
Temperature of Pumped Fluids .....................................................160oF............................................................... 71oC
Inlet Port..................................................................................................................................................2 x 1-1/2” BSP
Discharge Port...............................................................................................................................................2 x 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............................................................................................................................Nickle Aluminum Bronze
Volumetric Efciency @ 800 RPM...........................................................................................................................0.96
Mechanical Efciency @ 800 RPM .........................................................................................................................0.85
LP250-3100 Specications
U.S. Metric
Volume...........................................................................................25.7 GPM .............................................. 97.3 L/min
Discharge Pressure.......................................................................2030 PSI .....................................................140 Bar
Inlet Pressure ................................................................................90 PSI..........................................................6.2 Bar
Speed...................................................................................................................................................Up to 1000 RPM
Plunger Diameter...........................................................................1.30”.............................................................32 mm
Stroke............................................................................................1.65”.............................................................42 mm
Crankcase Oil Capacity.................................................................116 .oz....................................................3.43 liters
Temperature of Pumped Fluids .....................................................86oF................................................................. 30oC
Inlet Port..................................................................................................................................................2 x 1-1/2” BSP
Discharge Port...............................................................................................................................................1 x 1” BSP
Crankshaft Mounting .....................................................................................................................................Either Side
Shaft Rotation..............................................................................................................Top of Pulley Towards Fluid End
Weight ...........................................................................................126 lbs. .......................................................... 57 kg
Crankshaft Diameter............................................................................................................................................35 mm
Valve Casing............................................................................................................................Nickle Aluminum Bronze
NPSHR..........................................................................................25.6 ft. of Head ........................7.8 meters of Water
RPM GPM 600 PSI 800 PSI 1000 PSI 1600 PSI 2030 PSI
500 12.9 5.4 7.1 8.9 14.3 18.1
600 15.4 6.4 8.6 10.7 17.1 21.7
700 18 7.5 10.0 12.5 20.0 25.4
800 20.6 8.6 11.4 14.3 22.8 29.0
900 23.1 9.6 12.9 16.1 25.7 32.6
1000 25.7 10.7 14.3 17.8 28.6 36.2
LP250-3100 PULLEY SELECTION AND
HORSEPOWER REQUIREMENTS

4
LP122A-3100 & LP250-3100 Exploded View

5
Item Part # Description Qty.
1 07759 Crankcase 1
2 13000 Oil Filler Plug 1
3 05940 Cover Plate 1
3A 07223-0100 Spring Washer 2
3B 05051-0100 Hexagon Screw 2
4 06085 Crankcase Cover 1
5 07104 O-Ring 1
6 07186 Oil Sight Glass with Gasket 1
8 06086 Oil Dipstick 1
9 01009 O-Ring 1
10 01010-0100 Screw 4
11 01011-0400 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 05376 Shaft Protector 1
22 13242 Crankshaft 1
23 13243 Key 1
24 13340 Connecting Rod Assy. 3
24A 13277 Hex Screw 6
24B 13278 Spring Washer 6
25 13341 Crosshead Plunger
Base Assembly 3
28 13232 Crosshead Pin 3
29A 07735 Centering Sleeve 3
29B 07736 Plunger Pipe (LP122A-3100) 3
29B 13022 Plunger Pipe (LP250-3100) 3
29C 07737-0100 Plunger Bolt 3
29D 07161A-0100 Gasket for Bolt 3
29E 06618 Spacer Pipe 3
30 07779 Flinger 3
Item Part # Description Qty.
31 07133 Radial Shaft Seal 3
35 13342-0100 Seal Sleeve (LP122A-3100) 3
35 04138 Seal Sleeve (LP250-3100) 3
35A 06619 O-Ring 3
35B 13141-0001 O-Ring (LP250-3100) 3
36 13415 Grooved Ring (LP122A-3100) 3
36 13025 Grooved Ring (LP250-3100) 3
36A 13416A-0100 Pressure Ring (LP122A-3100) 3
36A 06700 Pressure Ring (LP250-3100) 3
36B 06174 Drip Shield 3
37 04124 Support Disc (LP250-3100) 3
39 07744-0100 Pressure Ring (LP122A-3100) 3
39 13026-0100 Pressure Ring (LP250-3100) 3
40 07745 Sleeve (LP122A-3100) 6
40 13027 Sleeve (LP250-3100) 6
41 07746-0100 Support Ring (LP122A-3100) 3
41 06702 Support Ring (LP250-3100) 3
42 06589 Plug, 1/8” BSP 3
42A 07204-0100 Steel Ring 3
43 13343-3000 Valve Casing 1
44 07748-0300 Valve Seat 6
44A 07150-0001 O-Ring 6
45 07749-0100 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 13044-0100 Plug 1” BSP 1
55 13322-0100 Plug, 1” BSP 1
LP122A-3100 & LP250-3100 Spare Parts List
LP122A-3100 & LP250-3100 Repair Kits
LP122A-3100 Plunger Packing Kit
# 09575
Item Part# Description Qty.
35A 06619 O-Ring 3
36 13415 Grooved Ring 3
36B 06174 Drip Shield 3
40 07745 Sleeve 6
LP250-3100 Plunger Packing Kit
# 09739
Item Part# Description Qty.
35A 06619 O-Ring 3
35B 13141-0001 O-Ring 3
36 13415 Grooved Ring 3
40 07745 Sleeve 6
Valve Assembly Kit
#09576
Item Part # Description Qty.
44 07748-0300 Valve Seat 6
44A 07150-0001 O-Ring 6
45 07749-0300 Valve Plate 6
46 07750 Valve Spring 6
47 07752 Spring Tension Cap 6
48A 06577 O-Ring 6
Oil Seal Kit
# 09577
Item Part# Description Qty.
31 07133 Radial Shaft Seal 3

6
LP122A-3100 & LP250-3100 Repair Instructions
1. With a 30mm wrench, re-
movethesix(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
intothespringretainerand
pulling straight out.
2. Todisassemblethevalve,screwtheboltintotheretaineruntil
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 & 36A), drip shield for
LP122A-3100 only (36B), v-sleeves (40 & 36), support ring (41)
and o-rings (35A) from the manifold and seal sleeve, respectively.
LP250-3100 pumps also have a support disc (37) and an O-ring
(35B) for the seal sleeve. Examine seals carefully and replace if
worn. Clean all parts.
44A 44 45 48 47
LP122A-3100 Only LP250-3100 Only LP250-3100 Only

7
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 recom-
mendscleaningthethreadswithacetoneorothersuitablecleaner.
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. (35 Nm). BE CERTAIN ALL PARTS
ARE CENTERED WITH THE BOLT!
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 lm
of oil.
29E 29A 29B 29D 29C
LP122A-3100 & LP250-3100 - Repair Instructions
9. Lubricate seal (36). Place seal (36) and drip shield (36B for
LP122A-3100 only), and pressure ring (36A) into the seal sleeve
(35). Assemble the O-ring (35A) onto seal sleeve and lubricate.
LP250-3100 has an additional O-ring (35B).
10. Place support ring (41) and
v-sleeves (40) into valve
casing. For LP250-3100, the
support disc (37) is placed
in the manifold before the
support ring.
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).
Replacewornpartsnecessary.Note:Alwaysuseanewcop-
per gasket (29) when repairing the plunger assembly.
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.
29E 29A 29B 29D 29C
LP122A-3100 Only LP250-3100 Only

8
11. Press seal sleeve assembly
into the manifold and seat
rmly. 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 rmly until
seated against the crank-
case.
15.ReplaceplugwithO-ring(48,
& 48A) and tighten to 160
ft.-lbs. (217 Nm).
14. Next,placevalveassemblies
(46A) into manifold after rst
lubricating the O-ring (44A).
Seat rmly into manifold.
13. Tighten hex nuts (49A) in a cross-
wisepattern(shown above)to60
ft.-lbs. (81 Nm).
16. Fill crankcase with approxi-
mately 116 uid ounces of
GiantoilorequivalentSAE90
industrial gear oil and check
oillevelofthecrankcasewith
the dipstick. Proper level is
center of two lines. Reinstall
yourGiantLPpumpintoyour
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]
64 2 7
8135
LP122A-3100 & LP250-3100 - Repair Instructions

9
Pump System Malfunction Troubleshooting
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
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
Water in crankcase High humidity Reduce oil change interval
Worn seals Replace seals
Noisy Operation Worn bearings Replace bearings, Rell crankcase
oil with recommended lubricant
Cavitation Check inlet lines for restrictions
and/or proper sizing
Rough/Pulsating Worn packing Replace packing
Operation with Inlet restriction Check system for stoppage, air Pres-
sure Drop leaks, correctly sized inlet
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
Rated, Pressure ow 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

10
Position Item# Description Torque Amount
10 01010-0100 Screw, Cover 125 in.-lbs. (14 Nm)
17 07114-0100 Hex Screw, Bearing Cover 125 in.-lbs. (14 Nm)
24A 13277 Hex Screw, Connecting Rod 250 in.-lbs. (28 Nm)
29C 07737-0100 Plunger Bolt 26 ft.-lbs. (35 Nm)
48 06089 Plug, Valve 160 ft.-lbs. (217 Nm)
49A 06577 Nut, Stud Bolt 60 ft.-lbs. (81 Nm)
LP122A-3100 & LP250-3100 Torque Specications
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”)
Preventative Maintenance Check List & Recommended Spare Parts List
Check Daily Weekly 50 hrs
Every
500 hrs
Every
1500 hrs
Every
3000 hrs
Oil Level/Quality X
Oil Leaks X
Water Leaks X
Belts, Pulley X
Plumbing X
Recommended Spare Parts
Oil Change p/n 01154 X X
Seal Spare Parts (1 kit/pump)
(see page 5 for kit list)
X
Oil Seal Kit (1 kit/pump)
(see page 5 for kit list)
X
Valve Spare Parts (1 kit/pump)
(see page 5 for kit list)
X

11
LP122A-3100 & LP250-3100 Dimensions - Inches (mm)

GIANT INDUSTRIES, INC., 900 N. Westwood Avenue, P.O. Box 3187, Toledo, OH 43607
PHONE: [phone], FAX: [phone], www.giantpumps.com
  Copyright 2012 Giant Industries, Inc.
06/12 LP122A_LP250-3100.indd
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-serve car wash applications, the discharge
manifolds will never fail, period. If they ever fail, we will replace them free of charge.
Ourotherpumpparts,usedinportablepressurewashersandincarwashapplications,
are warranted for ve years from the date of 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 modications made by the customer or third party.
6. The operation of pumps and or accessories exceeding the specications 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 work-
manship 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 war-
ranty 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
hereunderandthe MANUFACTURER SHALLNOTBELIABLEFOR FURTHERLOSS,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 WAR-
RANTIESORMERCHANTABILITYORFITNESSFORAPARTICULARPURPOSEANDALLSUCH
WARRANTIES ARE HEREBY DISCLAIMED AND EXCLUDED BY THE MANUFACTURER.