Giant GP7122 User's Manual
Contents
1. 39B 06266 Support Ring 6 51 07354 O Ring 42 06754 Spiral Ring Packing 6 51C 06760 Inlet Valve Seat 43 06755 Support Ring 6 51D 06761 Valve Plate 44 06756 Guide Ring 3 S1E 06762 Valve Spring 46 13390 Seal Ring 3 Discharge Valve Assembly Kit 09553 Oil Seal Kit 09225 Item Part Description Item Part Description Qty 51A 12056 Support Ring 32 07624 Radial ShaftSeal 3 51B 07354 O Ring 32A 07625 SealRing 3 51D 06761 Valve Plate 33A 07627 O Ring 3 51 06762 Valve Spring 52C 06764 Discharge Valve Seat GP7122 TORQUE SPECIFICATIONS Position Item Description Torque Amount 24 13406 Inner Hexagon Screw 30 ft Ibs 36 13138 Plunger 33 ft Ibs 49A 13160 Nut 103 ft Ibs 58C 07702 Hexagon Screw 155 ft Ibs GP7122 REPAIR INSTRUCTIONS NOTE Always take time to lubricate all metal and non metal parts with a light film of oil before reassembling This step will help ensure proper fit at the same time protecting the pump non metal parts elastomers from cutting and scoring TO CHECK VALVES 1 Lossen and remove screws 58C with a 24mm socket wrench 4 Take out valve assemblies 52 amp 51 using either tool part 07704 or a stud bolt 2 Take plugs 58 out of valve casing 50 by tightening screws 58C against valve casing with two screws 3 Remove the compression spring 57 O Ring 58A and support ring 58B 51C Suction 52C Discharge 5 Valve seats 51 and 52C are pressed out of spacer pipe2. 40 9 56 4 3 650 18 4 30 7 1 44 5 61 4 700 19 7 32 9 1 47 6 65 7 2 ER 750 9 9 35 4 51 3 Pressure PSI i HORSEPOWER RATINGS We recommend a 1 1 service factor be specified when selecting an electric motor as the power source The rating shown are the power requirements for the pump Gas engine power outputs must be To compute specific pump horsepower requirements approximately twice the pump power requirements use the following formula shown above GPM X PSI _ hp 1400 Exploded View GP7122 Kai a gt o gt N c E 9 o PART 07600 13000 07601 07602 07603 06225 13133 13134 07606 07182 07607 07608 07184 07610 07611 07612 13405 07614 13182 13183 13184 07619 07225 0100 13136 07622 13154 07623 07624 07625 07626 07627 07628 13137 06748 06749 22764 06750 06751 06752 07150 GP7122 PARTS LIST DESCRIPTION Crankcase Oil Filler Plug Assembly Crankcase Cover Seal for Crankcase Cover Oil Dip Stick O Ring Dip Stick Hexagon Screw Spring Washer Drain Plug Gasket Drain Plug Bearing Cover Radial Shaft Seal O Ring for Bearing Cover Taper Roller Bearing Fitting Disc Shim Shaft Protector Crankshaft Key Connecting Rod Assy Crosshead Assy Crosshead Pin Cover Plate Hexagon Screw Grommet Disc Cover Eye Bolt Radial Shaft Seal Seal Ring Seal Retainer
3. THE LIMITED WARRANTY SET FORTH HEREIN IS IN LIEU OF ALL OTHER WARRANTIES OR REPRESENTATION EXPRESS OR IMPLIED INCLUDING WITHOUT LIMITATION ANY WAR RANTIES OR MERCHANTABILITY OR FITNESS FORAPARTICULAR PURPOSE AND ALL SUCH WARRANTIES ARE HEREBY DISCLAIMED AND EXCLUDED BY THE MANUFACTURER Phone 419 531 4600 FAX 419 531 6836 www giantpumps com Copyright 2001 Giant Industries Inc 9 01 GP7122 PM6
4. to 90 PSE Plunger Diameter oues dette tt aie rue ED Obs 22mm MunPidesin MEE 48mm cpu M o 48mm Key dium a a 14mm Crankshaft Mounts Either side E Top of pulley towards manifold Temperature of Pumped Fluids eoe toutes oeste neon de PER Up to 140 F Inici oec EE 2 1 1 4 BSP WU ATS uico oka re SERRE NR MISSAM CHARME ANE DU NE 2 3 4 BSP DIT TT 374 lbs Crankcase OIl Capacity MT 1 6 Gal Pluie End Material E Stainless Steel Volumetric Efficiency 750 RPM sss 89 Mechanical Efficiency 750 83 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 Positive inlet pressures are recommended 2 convert to FNPT threads add 13377 0100 Adapter and 13376 0100 Seal To convert to FNPT threads add 14081 0100 Adapter and 14082 Seal System Requirements No Unloader or Regulator allowed Must use a safety valve and dump gun go 8 26 8 2 a ee Q 23 T i 0 500 600 700 0 2900 5800 8700 11 600 2 RPM Pressure PSI NPSHR Chart GP7122 HORSEPOWER REQUIREMENTS 90 85 9 550 x E 26 1 37 8 a 600 7 9 16 9 28 2
5. 51F by hitting the valve plate 51D with a socket extention 6 Check surfaces of valve plate 51D valve seat 51C 52C o rings 51A and support rings 51B Replace worn parts GP7122 REPAIR INSTRUCTIONS 7 When reassembling The inlet valve seat 51C is Imm smaller in diameter than the discharge valve seat 52C Inlet valve seats are marked S and always have to be installed first Discharge valve seats are marked P and are always to be installed on top of inlet valve Plugs 58 are to be tensioned down evenly with screws 58C and in crosswise pattern at 155 ft lbs Valve Seat identification markings TO CHECK SEALS 8 Loosen nuts 49A witha 9 With a rubber mallet tap the 10 Remove cover plate 30 24mm socket wrench back of the valve casing 50 with a 10mm socket wrench and pull the valve casing off the stud bolt 49 11 By gripping hex flats sepa 12 Remove tension spring 40 13 Pull seal sleeves 38 and rate plunger 36 from cross from seal retainer 38 plungers 36 out of their head 25 by means of two open end wrenches size fittings in the crankcase 22mm and 27mm 1 using ring groove as a guide GP7122 REPAIR INSTRUCTIONS CAUTION Don t loosen the 3 plunger 36 before the valve casing has been removed otherwise the plunger 36 could hit against the spacer pipe 51F when the pump is being turned 14 Remove circlip ring 48 from seal sleeve 38 R
6. O Ring for Seal Retainer Circlip for Seal Retainer Oil Scraper Flinger Plunger Seal Sleave Serrated Pin Leakage Gasket O Ring Seal Case O Ring m UA QV U U wow 00 gt 00 UU Fa Fa Fa PART DESCRIPTION 06266 Support Ring 07338 Tension Spring 06753 Support Disc 06754 Spiral Ring Packing 06755 Support Ring 06756 Guide Ring 06757 Pressure Ring 13390 Seal Ring 06758 Spacer Disc 07690 Circlip 13159 Stud Bolt 13160 Hexagon Nut 06759 Valve Casing 13162 Centering Stud 12056 Support Ring 07354 O Ring 06760 Inlet Valve Seat 06761 Valve Plate 06762 Valve Spring 06763 Spacer Pipe 06764 Discharge Valve Seat 06078 Tension Spring 07699 Plug 07700 O Ring 07693 Support Ring 07702 Hexagon Screw 07661 Copper Ring Gasket 13150 Plug 3 4 BSP 13151 Plug 1 1 4 BSP 06765 Connecting Screw 06766 Connection Ring 06767 Seal Ring 06589 Plug 07258 0100 Steel Ring 13362 Disc for Crankshaft 13358 Hexagon Screw 06588 Screw in Connector 06768 Threaded Elbow 06769 Curved Leakage Pipe 07704 Valve Tool not shown 6 3 3 6 6 3 3 3 3 3 8 8 1 2 6 6 3 6 6 6 3 3 3 3 3 N ka e e e Fa Ne NY ba Fa Plunger Packing Kit 09551 GP7122 REPAIR KITS Inlet Valve Assembly Kit 09552 Item Part Description Qty Item Part Description 9 07150 O Ring 6 51 12056 Support Ring
7. Triplex Ceramic Plunger Pump d Operating Instructions Repair and Service 7122 Contents Installation Instructions page 2 Pump Specifications page 3 Exploded View page 4 Parts List page 5 Kits page 6 Torque Specifications page 6 Repair Instructions pages 7 10 Dimensions page 11 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 IMPORTANT To guarantee weep return it is essential that the inlet line is fitted to the support screw 62 If the inlet line is mounted to the other side of the pump then the whole connection part 5 62 62B 64 69 71 must be fitted to the same inlet side 3 A tube fitting on the s
8. crews 24A to 30 ft Ibs CAUTION Connecting rod 24 has to be able to be slightly moved sidewise at the stroke journals 27 Reassemble cover 4 and seal 5 onto crankcase 1 Fasten with hexagon screws 10 28 Reinstall shim 33C and seal adaptor 33 with radial shaft seal 32 ring 32A and o ring 33A onto crankcase 1 29 Reinstall remainder of fluid end as described above in Assemble Valve Casing section 21 and 22 above 10 GP7122 Dimensions Inches Fitting Key a lt to Centering Hole M10 Discharge Connection 2 x 3 4 BSP 4 x 17 260 Connection 2 x 1 1 4 BSP 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 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 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 Ninety 90 days from the date of shipment for all Giant accessories This warranty is
9. e move spacer disc 47 and seal ring 46 from seal sleeve Replace worn or damaged parts 15 Remove leakage gasket 38B from serrated pin 38A on the seal sleave 38 Check o ring 38C for damage and replace if necessary IMPORTANT The 3 2 mm diameter bore of the leak age gasket 38B must be inserted directly on the serated pin 38A of the seal sleeve 38 The leakage gasket must fit snugly to the seal so that the bevelled surface of the gasket faces outwords 16 Remove support disc 41 seal unit 42 43 44 and pressure ring 45 of seal sleeve 38 Examine seals for signs of wear or cavi tation and if necessary replace NOTE 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 17 Examine plunger 36 for signs of wear or cavitation If the surface of the plunger is worn screw out the plunger with a pressure to drop 27mm tool Clean centering and front surface of crosshead with plunger 25 Thread new plunger carefully through oiled seals in seal sleave Coat thread of new plunger lightly with bonding agent e g loctite GP7122 REPAIR INSTRUCTIONS TO ASSEMBLE VALVE CASING 18 Check O rings 39A and support rings 39B on seal case 39 Clean surfaces of seal sleeves 38 in crankcase 1 and sealin
10. g surfaces of valve casing 50 Insert seal sleeve with plunger into crankcase guide Turn crank shaft to 22 until plunger with crosshead 25 pushes against plunger tighten plunger 36 to 26 ft lbs 19 Push valve casing carefully over O rings of seal case and centering studs 50A Tighten nuts 49A to space 103 ft lbs TO DISASSEMBLE GEAR END 20 Take out plunger 36 and seal sleeves 38 as described above Drain oil 21 After removing the circlip ring 33B pry out seal adapter 33 with a screw driver 22 Check seals 32 32A 33A and surfaces of plunger base 25 23 Remove crankcase cover 4 Loosen inner hexagon screws 24A on the connecting rods 24 and push con rod halves as far into the crosshead guide as possible CAUTION Connecting rods 24 are marked for identification Do not twist connecting rod halves Connecting rod is to be reinstalled in the same position on crankshaft journals 24 Check surfaces of the connecting rod 24 and crankshaft 22 25 Take out bearing cover 14 to one side and push out crankshaft 22 taking particular care that the connecting rod 24 doesn t bend CAUTION Ring 32A must always be installed so that the seal lip on the inside diameter faces the oil 26 Reassemble in reverse order Regulate axial bearing clearance minimum 0 1mm maximum 0 15mm by means of fitting disc 20A The crankshaft 22 should turn easily with little clearance Tighten inner hexagon s
11. ide of the pumphead which allows the circulation of water between the valve casing and seal sleeves to take place The tube fitting must always be mounted on the same side as the suction line 4 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 IMPORTANT OPERATING CONDITIONS Failure to comply with any of these conditions invalidates the warranty 1 Prior to initial operation add oil to crankcase so that the oil level is between the two lines on the oil dipstick DO NOT OVERFILL SAE 80 Indus trial Gear oil may be used Crankcase oil should be changed after the first 50 hours of operation then at regular intervals of 500 hours or less de pending on operating conditions 5 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 6 Crankshaft rotation on Giant Industries Inc pumps should be made in
12. limited to repair or replacement of pumps and accessories of whichthe 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 EE The operation of pumps and or accessories exceeding the specifications 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 workmanship or failure of material AReturned 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 FURTHERLOSS DAMAGES OR EXPENSES INCLUDING INCIDENTAL AND CONSEQUENTIAL DAMAGES DIRECTLY OR INDIRECTLY ARISING FROM THE SALE OR USE OF THIS PRODUCT
13. 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 chart on page 3 7 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 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 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 Specifications Model GP7122 VOLG E E Up to 9 9 GPM Discharge Pressure icici nran aA E AEAEE Up to 10 000 PSI 2 eene Up to 750 RPM Inlet EE eee eegen Up
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