Triplex Ceramic Plunger Pump Operating Instructions/ Repair and Service Manual Model LP122A-3100 Updated 11/06 Contents: Installation Instructions: Pump Specifications: Exploded View: Parts List/Kits: Repair Instructions: Trouble Shooting: Recommended Spare Parts List: Torque Specifications: Pump Mounting Selection Guide: Dimensions: Warranty Information: page 2 page 3 page 4 page 5 pages 6-8 page 9 page 10 page 10 page 10 page 11 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. 4. Use of a dampener is necessary to minimize pulsation at drive elements, plumbing, connections, and other system areas.
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 ..........................................................................................................
Exploded View - LP122A-3100 4
SPARE PARTS LIST - LP122A-3100 PUMP ITEM 1 2 4 5 6 8 9 10 11 12 13 14 15 16 17 20 20A 20B 21 22 23 24 25 28 29A 29B 29C 29D PARTNO. 07759 13000 06085 07104 07186 06086 01009 01010-0400 08094 07109-0400 07182 07111 07112 07113 07114-0100 07116 07117 13001 07118 13242 13243 13340 13341 13232 07735 07736 07737-0100 07161A-0100 ITEM 29E 30 31 35 35A 36 36A 36B 39 40 41 43 44 44A 45 46 46A 47 48 48A 49 49A 49B 50 50A 52 53 54 55 DESCRIPTION QTY.
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.
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 back of the pump. 29E 29A 9. 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. 29D 29C 6.
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 7 8 1 3 5 13. Tighten hex nuts (49A) in a crosswise pattern (shown above) to 60 ft.-lbs. 16.
PUMP SYSTEM MALFUNCTION MALFUNCTION CAUSE REMEDY The Pressure and/ or the Delivery Drops 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 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
Preventative Maintenance Check-List & Recommended Spare Parts List Check Daily Oil Level/Quality Oil Leaks Water Leaks Belts, Pulley Plumbing Weekly 50hrs Every 500 hrs Every 1500 hrs Every 3000 hrs X X X Oil Change p/n 1154 Seal Spare Parts (1 kit/pump) X X Recommended Spare Parts X X X (See page 5 for kit list) Oil Seal Kit (1 kit/pump) (See page 5 for kit lit) X Valve Spare Parts (1 kit/pump) X (See page 5 for kit list) LP122A-3100 TORQUE SPECIFICATIONS Position Item# 10 17 24A 29C 48 4
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.
