Giant GP7150A User's Manual
Contents
1. 1 2 NPT 3 66 13362 Disc For Crankshaft 3 67 13358 Hexagon Screw This item may be removed to add a third v sleeve QTY WWW 0 o WDWWDADWBADDDAAAADAANK KK WWW REPRE Plunger Packing Kit 09526 GP7150A Item 38A 38B 39A 41 42 Part 13156 06258 07796 07636 07638 Description O Ring O Ring Compact Ring O Ring V Sleeve avo vole Plunger Packing Kit 9220 GP7155A amp GP7255A Item 38A 38B 39A 41 42 Part 13156 07721 07223 13158 07711 Description O Ring O Ring Compact Ring O Ring V Sleeve avou Oil Seal Kit 09221 Item 32 32A 33 Part 07624 07625 07627 Description Radial Shaft Seal Shaft Seal O Ring wool Valve Kit 09606 Item Part Description 51B 08282 Valve Spring Guide SIC 07732 0100 Valve Spring 51D 13164 Valve Plate SIE 08283 Valve Seat SIF 07653 O Ring 51G 13166 Support Ring 51H 07266 O Ring 56A 07658 O Ring 56B 07635 Support Ring 56C 13166 Support Ring 56D 07653 O Ring nnn Note When ordering a valve kit for a pump produced prior to 11 03 order kit 09222 which replaces part 08281 with p n 13163 Kit 09222 does not require p n 08282 Specifications Model GP7150A DS E WSs MIELFIC 01110 54 5 GPM iscsi 206 LPM Discharge 690 esesiieiieiiissesii2. 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 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 The operation of pumps and or accessories exceeding the specifications set forth in the Operations Manuals provided by Giant Industries Inc DRN 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 ret
3. 1900 131 Bar DPC casscccdaivsceerssaceesretoues Aeveded sts E e 700 RPM Inlet PreSSUT E ennerien 140 PSL 10 Bar Plunger Diameter 0 cccceesseeeeeeeeeeeees WOT sasons 50mm Plunger 6016 SIS 48mm Crankshaft Diameter LSI eee 48mm Key Widsets O99 ese 14mm Crankshaft Mounting sese Either side Shaft ROOM Max Temperature of Pumped Fluids Inlet POrts eR Top of pulley towards manifold 140 F cates 60 C i 2 2 1 2 NPT Discharge PORS Sra 2 1 1 4 NPT MES 374 IDS 170 kg Crankcase Oil Capacity 1 6 Gal wee 6 0 liters Fluid End Material cece ceceesseeseecneeceeeeseceseeeseeeaaeeneens Bronze Mechanical Effecency 700 RPM 4 a sss 0 83 Volumetric Effecency 700 RPM sass sss 0 96 Consult the factory for special requirements that must be met if the pump is to operate beyond one or more of the limits specified above 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 siz
4. 2 and 27 Pull seal sleeves 39 out of their fittings in the crankcase Take seal case 38 out of seal sleeve 39 Examine plunger parts 36A 36D seals 42 39A and O rings When replacing plunger pipe 36B tighten tension screws 36C to 30 ft Ibs Replace worn parts grease seals with Silicone before installing CAUTION Don t loosen the 3 plunger connections 36A before the valve casing has been removed otherwise the tension screw 36C could hit against the spacer pipe 51E when the pump is being turned Seal life can be increased if the pretensioning allows for a little leakage This assists lubrication and keeps the seals cool It is therefore not necessary to replace seals before the leakage becomes too heavy and causes output and operating pressure to drop MOUNTING VALVE CASING Check O rings on seal case 38 Clean surfaces of seal sleeves in gear box and sealing surfaces of valve casing Push valve casing carefully on O rings of seal case and centering studs 50A Tighten nuts 49A to 103 ft Ibs TO DISASSEMBLE GEAR Take out plunger and seal sleeves as described above Drain oil After removing the circleclip ring 33B lever out seal retainer 33 with a screw driver Check seals 32 32A 33A and surfaces of crosshead Remove crankcase cover 4 Loosen inner hexagon screws on the connecting rods 24 and push con rod halves as far into the crosshead guide as possible Note Connecting rods are marked for identifica
5. Triplex Ceramic Plunger Pump Manual Models GP7150A GP7155A GP7255A Contents Installation Instructions GP7155A GP7255A page 2 Pump Specifications page 3 Parts List Exploded View pages 4 5 Pump Specifications GP7150A page 6 Recommended Spare Parts List page 7 Repair Instructions page 7 Dimensions back page Updated 03 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 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 restric tions that can cause cavitation Teflon tape should be used to seal all joints If pumps are to be oper ated at temperatures in excess of 140 F it is impor tant 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
6. e that corresponds with the pump GPM HORSEPOWER INFORMATION Horsepower ratings shown are the power require ments for the pump Gas engine power outputs must be approximately twice the pump power require ments shown above We recommend that a 1 1 service factor be specified when selecting an electric motor as the power source To compute specific pump horsepower requirements use the following formula GPH X PSI 1450 HP GP7150A PULLEY SELECTION amp HORSEPOWER REQUIREMENTS PUMP MOTOR PULLEY PULLEY RPM GPM 800 PSI 1000 PSI 1300 PSI 1500 PSI 1900 PSI 12 75 11 00 600 467 267 334 434 500 634 GP7150A GP7155A GP7255A_REPAIR INSTRUCTIONS TO CHECK VALVES Lossen plugs 58 take out tension spring 57 and then remove the complete valve 51 with either a valve tool or an M16 hexagon screw Remove valve adapter 56 and tension spring 57 with pull out tool size 5 There is an O ring 51G under both the suction and the discharge valve each of which can be removed with a bent piece of wire To disassemble valve hit the top of the valve plate C carefully with a bolt and press the valve seat A out of the spacer pipe E Check sealing surfaces and replace worn parts Check O rings and support rings Tighten plugs 58 to 107 ft Ibs TO CHECK SEALS AND PLUNGER PIPE Loosen nuts 49A and remove pump head Separate plunger connection 36A from crosshead 25 by means of two open end wrenches size 2
7. g an electric motor as the power source To compute specific pump horsepower requirements use the following formula GPH X PSI 1450 HP GPM GP7155A GP7255A PULLEY SELECTION amp HORSEPOWER REQUIREMENTS PUMP MOTOR PULLEY puey RPM eM s00 Psi 1000 Psi 1200 P 1500 Ps 2000 Ps 12 75 9 00 479 450 257 321 418 482 643 12 75 11 70 638 600 343 429 557 643 85 7 Exploded View GP7150A GP7155A GP7255A ITEM PART DESCRIPTION 1 07600 Crankcase 2 13000 Oil Filler Plug Assembly 4 07601 Crankcase Cover 5 07602 Gasket Crankcase Cover 8 07603 Oil Dip Stick 9 01009 O Ring Dip Stick 10 13133 Hexagon Screw 11 13134 Spring Washer 12 07109 Drain Plug 13 07182 Gasket Drain Plug 14 07607 Bearing Cover 15 07608 Radial Shaft Seal 16 07184 O Ring 20 07610 Taper Roller Bearing 20A 07611 Fitting Disc Shim 21 07612 Shaft Protector 22 13405 Crankshaft 23 07614 Key 24 13182 Connecting Rod Assy 25 13183 Crosshead Assy 28 13184 Crosshead Pin 30 07619 Cover Plate 30A 07225 0100 Hexagon Screw 30B 13136 Grommet 30C 08280 Washer 30D 13154 Cover Plate 31 07623 Eye Bolt 32 07624 Radial Shaft Seal 32A 07625 Shaft Seal 33 07626 Seal Retainer 33A 07627 O Ring 33B 07628 Circlip 33C 07249 Fitting Disc 34 13137 Oil Scraper 36 07706 Plunger Pipe Assy GP7155A GP7255A 36 A D 36 07630 Plunger Pipe Assy 36A D 36A 07667 Plunger Connection 36B 07793 Plunger P
8. ipe 50mm 36B 07666 Plunger Pipe 55mm GP7155A GP7255A 36C 07664 Tension Screw 36D 07665 Copper Ring 38 13155 Seal Case GP7155A GP7255A Spare Parts List GP7150A GP7155A GP7255A QTY ITEM PART DESCRIPTION 1 38 07794 Seal Case GP7150A 1 38A 13156 O Ring 1 38B 07721 O Ring GP7155A GP7255A 1 38B 06258 O Ring GP7150A 1 38C 07635 Support Ring GP7150A Only 1 39 13157 Seal Sleeve GP7155A GP7255A 12 39 07795 Seal Sleeve GP7150A 12 39A 07723 Compact Ring GP7155A GP7255A 3 39A 07796 Compact Ring GP7150A 2 40 07797 Support Disc GP7155A GP7255A 2 41 13158 O Ring GP7155A GP7255A 2 41 07636 Tension Spring GP7150A 2 42 07711 V Sleeve GP7155A GP7255A 2 42 07638 V Sleeve GP7150A 1 5 43 07712 Pressure Ring GP7155A GP7255A 1 43 07639 Pressure Ring GP7150A 1 44 07637 Support Ring GP7150A only 1 49 13159 Stud Bolt 3 49A 13160 Hex Nut 3 50 07790 Valve Casing GP7155A 3 50 07791 Valve Casing GP7255A 1 50 06628 Valve Casing GP7150A 8 50A 13162 Cylinder Stud 4 31 08288 Valve Assembly 8 SIA 08281 Spring Tension Cap 1 51B 08282 Valve Spring Guide 1 JE 07732 0100 Valve Spring 3 51D 13164 Valve Plate 3 51E 08283 Valve Seat 3 S1F 07653 O Ring 3 51G 13166 Support Ring 3 51H 07266 O Ring 3 56 13167 Valve Adaptor 3 56A 07658 O Ring 56B 07635 Support Ring 3 56C 13166 Support Ring 3 56D 07653 O Ring 3 57 133 Tension Spring 3 58 1310 Plug 59A 07661 Copper Ring 3 60 12251 Plug 1 1 4 NPT 3 6l 12252 Plug 2
9. roperly 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 pres sure operation in a pump system has many advantages But ifit is used carelessly and without regard to its potential hazard it can cause serious injury 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 Specifications Model GP7155A GP7255A eee i ais U S Metric VOUM kse AA 65 8 GPM 250 LPM Discharge Pressure iscsi 1300 PSI acis 100 Bar SPEC essen aes 2000 PSI 138 Bar 11916 65111 asena Ras Up to 700 RPM Plunger Diameter 2T ece 55mm Plunger Stroke cc ctecsveces ZOD e 52mm Crankshaft Diameter IS9 acis 48mm Key Widths tasa ees 14mm Crankshaft Mounting sssrini einean Either
10. side Shalt ROtati Othieccc d cchaicedssaciecdsasteccigenececteades sass eR Top of pulley towards manifold Max Temperature of Pumped Fluids 140 E eta 60 C Inlet Ports 080170040 suede PTE 2 2 1 2 NPT a 2 1 1 4 NPT WOLD STA ADS ees 170 kg Crankcase Oil Capacity 1 6 Gali siseses 6 0 liters Fluid End Material GP7155A assiscecessecesaceeieireeeess Bronze Fluid End Material GP7255A ue ee eeseeeeceseceeeceaeeeaeeeeeeaeens Nickle Plated Spheroidical Cast Iron Mechanical Effecency 700 RPM eerren 0 83 Volumetric Effecency 700 RPM uu 0 96 Consult the factory for special requirements that must be met if the pump is to operate beyond one or more of the limits specified above 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 HORSEPOWER INFORMATION Horsepower ratings shown are the power require ments for the pump Gas engine power outputs must be approximately twice the pump power require ments shown above We recommend that a 1 1 service factor be specified when selectin
11. the event of a blockage or the use of a shut off 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 IMPORTANT OPERATING CONDITIONS Failure to comply with any of these condi tions invalidates the warranty 1 Prior to initial operation add oil to crankcase so that oil level is between the two lines on the oil dipstick DO NOT OVERFILL Use Giant Recommended Oil p n 01154 which is equiva lent to SAE 85 90W Industrial Grear Lube Crank case oil should be changed after the first 50 hours of operation then at regular intervals of 500 hours or less depending on operating conditions 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 un loader 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 obtained from the charts on pages 3 amp 6 6 Before beginning operation of your pumping system remember Check that the crankcase and seal areas have been p
12. tion Do not twist con rod halves Con rod is to be reinstalled in the same position on shaft journals Check surfaces of connecing rod and crankshaft 22 take out bearing cover to one side and push out crankshaft taking particular care that the conrod doesn t gt bent Note Seal 32A must always be installed so taht the seat up on the inside diameter faces the oil Reassemble in revers order Regulate axial bearing clearance minimum 0 1mm maximum 0 15 by Preventative Maintenance Check List amp Recommended Spare Part List Check Daily Weekly 50hr Every Every Every 500 hr 1500 hr 3000hrs 190 9 11 3 8 819 Oil Change p n 01154 X Plunger Packing Kits 1_kit Pump See page 5 for kit list Oil Seal Kit 1 kit Pump See page 5 for kit list Valve Assembly Kit 1 kit pump GP7150A GP7155A GP7255A SERIES DIMENSIONS INCHES mm KEY 140350704 l NPT 2 Abst ras a 93 3 657 143 5597 5 5 2 037 48 a u ID TAPPED HOLE 260 10 2471 t 2 172 NPT INLET 2297 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
13. urn 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 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 Ave P O Box 3187 Toledo Ohio 43607 419 531 4600 FAX 419 531 6836 Copyright 2006 Giant Industries Inc 03 06 GP7150A GP7155A GP7255A PM6
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