Giant GP7170-4000 User's Manual
Contents
1. Reassemble cover 4 and seal 5 onto crankcase 1 Fasten with hexagon screws 10 Reinstall shim 33C and seal adapter 33 with radial shaft seal 32 and o ring 33A onto crankcase 1 CAUTION Radial shaft seal 32 must always be installed so that the seal lip on the inside diameter faces the oil Reinstall remainder of fluid end as described above GP7170 4000 TORQUE SPECIFICATIONS Position Item Description Torque Amount ft Ibs 36C 07664 Plunger Tensioning Screw 26 49A 13160 Nut 103 Ka 05250 Inner Hexagon Screw 155 TImportant Check torque bi weekly on item 49A Preventative Maintenance Check List amp Recommended Spare Parts List Daily Weekly 50hrs Every Every Every 500 hrs 1500 hrs 3000 hrs Oil Level Quality Oil Leaks Water Leaks Belts Pulley X Plumbing X Recommended Spare Parts Oil Change X X Plunger Spare Parts 1 kit pump See page 5 for kit list Oil Seal Kit 1 kit pump See page 5 for kit lit Valve Spare Parts 1 kit pump See page 5 for kit list 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 portable2. remove firmly grasp both pieces and rock them back and forth to break the O ring seal on the O D of the valve seat Remove the inlet valves using the same procedure as above Unscrew the valve seat 51A from the spacer pipe 51E Remove the valve spring 51D and valve spring guide 51F and inspect for wear Replace parts as necessary Check surfaces of valve plate 51C valve seat 51A O rings 51B and replace worn parts To reinstall the inlet valves 51 screw the valve puller back into the top of the valve assembly 51 Lower the valve into the chamber and press firmly into the bottom of the chamber to ensure the valve is seated properly Install the tension spring 53 To reinstall the discharge valves press the discharge valve 51 into the pressure valve adapter 52 Push the entire assembly into the chamber Reinstall the tension spring 53 Reinstall the discharge casing 48 and tighten bolts 54 to 155 ft lbs in a criss cross pattern starting with the centermost 4 bolts and working outward To Change Seals Loosen nuts 49A with a 24mm socket wrench With a rubber mallet tap the back of the valve casing 50 and pull the valve casing off the stud bolt 49 Remove cover plate 30 with a 10mm socket wrench By gripping hex flats separate plunger assembly 36 from crosshead 25 by means of two open end wrenches size 22mm and 27mm CAUTION Do not loosen the 3 plunger bases 36A before the valve casing has been removed ot
3. Model GP7170 4000 Triplex Ceramic Plunger Pump Operating Instructions Repair and Service Manual Contents Pump Specifications Exploded View Parts List Kits Repair Instructions Torque Specifications Recommended Spare Parts List Warranty Information Installation Instructions page 2 page 3 page 4 page 5 pages 6 7 page 7 page 7 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 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 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 even
4. SP 1 36C 07664 Tensioning Screw 3 66 13362 Disc for Crankshaft 1 36D 07665 Copper Ring 3 67 13358 Hexagon Screw 1 37 05233 Intermediate Casing 1 07662 Slide Hammer Tool notshown 1 GP7170 4000 REPAIR KITS Plunger Packing Kit 09610 Inlet Valve Assembly Kit 09611 Jtem Part Description Qty Item Part Description Qty 39 05235 O Ring for Seal Retainer 3 SIA 05246 Valve Seat 1 42 05238 O Ring 3 51B 07653 O Ring for Valve Seat 1 4 05240 V Sleeve 9 SIC 05247 Inlet Valve Seat 1 47A 05242 O Ring 6 51D 07732 0100 Valve Spring 1 SIF 05248 Valve Spring Guide 1 Oil Seal Kit 09612 52A 07658 O Ring 2 Jtem Part Description Qty 32 07624 Radial Shaft Seal 3 33A 07627 O Ring 3 GP7170 4000 REPAIR INSTRUCTIONS NOTE Always take time to lubricate all metal and non metal parts with a light film of ol before reassembling This step will help ensure proper fit at the same time protecting the pump non metal parts elastomers from cutting and scoring 1 2 3 39D S 9 10 11 12 13 14 15 16 17 18 we 19 20 21 22 To Check Valves Loosen and remove screws 54 with a 10mm allen wrench Remove discharge casing 48 and valve tension springs 53 Remove the discharge valves 51 by screwing supplied valve puller into the top of the spacer pipe 51E and firmly sliding upward with the puller handle NOTE The pressure valve adapter 52 will typically come out attached to the discharge valve To
5. ateort sets Top of pulley towards manifold Temperature of Pumped Fluids eee J40 GE 60 C WING Ge E 2 1 1 4 NPT DiSCharge E 2 3 4 NPT Weight secsivscsiecasccteses scetsinestien ssavteceseatssscectapvereteenes ZTA le E 170 kg Crankcase Oil Capacity ce ceeceeeeeeeeeseeeeeeneees LOG ilinira 6 0 liters Fluid End Material sristi inian eon EEEE AE EE EE Stainless Steel GP7170 PULLEY SELECTION amp HORSEPOWER REQUIREMENTS PUMP MOTOR emer Loser EEN G 500s 750 st 000 Ps 1500 rel 12 75 11 45 500 60 0 214 321 429 643 HORSEPOWER RATINGS We recommend a 1 1 service factor be specified when selecting an electric motor as the power The rating shown are the power require source ments for the pump Gas engine power outputs must be approximately twice the To compute specific pump horsepower requirements pump power requirements shown above use the following formula GPM X PSI 1400 hp Exploded View GP7170 4000 GP7170 4000 PARTS LIST DEM PART DESCRIPTION QTY TEM PART DESCRIPTION QTY 1 06653 Crankcase 1 38 05234 Seal Sleeve 3 2 13000 Oil Filler Plug Assembly 1 39 05235 O Ring for Seal Retainer 3 4 07601 Crankcase Cover 1 40 05236 Pressure Ring 3 5 07602 Seal for Crankcase Cover 1 41 05237 Drip Return Ring 3 8 07603 Oil Dip Stick 1 42 05238 O Ring 3 9 01009 O Ring Dip Stick 1 43 05239 Pressure Ring 3 10 22706 Hexagon Screw 12 44 05240 Sleeve 9 II 06725 Spring Washer 12 45 05241 Sleeve Suppor
6. herwise the plunger assembly 36 could hit against the spacer pipe 52 when the pump is being turned Remove the intermediate casing 37 from the crankcase 1 Use two screwdrivers to pry the seal case 47 out of the intermediate casing 37 Remove pressure ring 43 V sleeves 44 sleeve support ring 45 seal tension spring 46 and O rings 47A Inspect parts for wear and replace as neces sary Remove the seal sleeve 38 O ring 39 pressure ring 40 V sleeve 44 O ring 42 and drip return ring 41 from the crankcase 1 Inspect parts for wear and replace as necessary Inspect the plunger pipe for cavitation cracks or any other signs of wear If replacing plunger pipe tighten plunger bolt 36C to 26 ft lbs Reassemble all parts in reverse order taking care to lubricate all seals and O rings with silicone grease prior to installa tion Reinstall plunger pipe assemblies 36 into intermediate casing 37 When installing the intermediate casing 37 and valve casing 50 be sure that the parts rest on the studs 50A and that they have not fallen out Reinstall valve casing 50 and tighten nuts 49A to 103 ft lbs To Change Oil Seals Remove C clip 33B from crankcase 1 and remove seal retainer 33 Remove O ring 33A and radial shaft seal 32 and replace as necessary Reinstall seal retainer 33 and secure with C clip 33B in crankcase NOTE Seal life can be increased if the pretensioning allows for a little
7. 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 23 To Disassemble Gear End Remove entire manifold and intermediate casing assembly using procedures described above Take out plunger assembly 36 Drain oil 6 24 25 26 27 28 29 Kc 30 31 32 wa GP7170 4000 REPAIR INSTRUCTIONS After removing the C clip 33B pry out seal adapter 33 with a screwdriver Check seals 32 and surfaces of plunger base 25 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 Check surfaces of the connecting rod 24 and crankshaft 22 Take out bearing cover 14 to one side and push out crankshaft 22 taking particular care that the connecting rod 24 doesn t bend 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 screws 24A to 30 ft lbs CAUTION Connecting rod 24 has to be able to be slightly moved sidewise at the stroke journals
8. 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 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 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 our won 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
9. 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 REPRESENTATION EXPRESS OR IMPLIED INCLUDING WITHOUT LIMITATION ANY WAR RANTIES OR MERCHANTABILITY OR FITNESS FORA 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 PHONE 419 531 4600 FAX 419 531 6836 www giantpumps com Copyright 2006 Giant Industries Inc 07 06 GP7170 4000 PM6
10. 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 GP7170 4000 LI E Metric Viel Lu Sc GEM Ener 320 LPM Discharge Pressure cceeeeeeeseceseceteeereeeneensees 1450 PSU eisein 100 bar DS EE Up to 700 RPM Ir WE Up to 90 PSI 10 bar Plunger Diameter cccececesseceeeeeeeeeeeeeeeeaees DAS gegen eg 63 mm Pl nger Stoke eweg ugdertoge eege eech ee so SE 52mm Crankshaft Diameter QOD siseaseccessiectivsssstevvins 52mm Key A reien are a eE E E E ETE 14mm Crankshaft Mountino 5 veccsccsscsctcsees sadestilests cases lessusssitvosssCevsveasedsisa nosseasveseseeee Either side Shalt RotaOttys gieren cetercstaouciedisesse tseluctemseneoteeutrbescmei
11. t Ring 3 12 07109 0400 Drain Plug 5 46 05071 Seal Tension Spring 3 13 07182 Gasket Drain Plug 2 47 05242 Seal Case 3 14 07607 Bearing Cover 2 47A 06667 O Ring 6 15 07608 Radial Shaft Seal 2 48 05243 Discharge Casing 1 16 07184 O Ring for Bearing Cover 2 49 06675 Stud Bolt 8 20 07610 Taper Roller Bearing 2 49A 06958 Hexagon Nut 8 20A 07611 Fitting Disc Shim 1 5 50 05244 Valve Casing 1 21 07612 Shaft Protector 1 50A 13162 Cylinder Stud 4 22 13405 Crankshaft 1 51 05245 Valve Assembly 6 23 07614 Key 1 SIA 05246 Valve Seat 6 24 13182 Connecting Rod Assy 3 51B 07653 O Ring for Valve Seat 6 25 13183 Crosshead Assy 3 SIC 05247 Valve Plate 6 28 13184 Crosshead Pin 3 51D 07732 0100 Valve Spring 6 30 06661 Cover Plate 1 SIE 08281 Spacer Pipe 6 30A 07225 0100 Hexagon Screw 4 SIF 05248 Valve Spring Guide 6 30B 13136 Grommet 4 52 05249 Pressure Valve Adapter 3 30C 08280 Disc 4 52A 07658 O Ring 6 31 07623 Eye Bolt 1 53 13173 Tension Spring 6 32 07624 Radial Shaft Seal 3 Ka 05250 Inner Hexagon Screw 8 33 06662 Seal Retainer 3 55 05251 Drip Return Connection 1 33A 13286 O Ring forSeal Retainer 3 55A 22764 Serrated Pin 1 33B 05229 Circlip for Seal Retainer 3 56 05252 Drip Return Plug 1 33C 05230 Fitting Disc 3 57 05253 O Ring 2 4 13137 Oil Scraper Flinger 3 58 05254 Leakage Seal 2 36 05231 Plunger Pipe Assembly 36A 36D 3 59A 06807 Steel Ring Gasket 1 36A 07667 Plunger Base 3 60 13151 Plug 1 1 4 BSP 1 36B 05232 Plunger Pipe 3 6l 12252 5000 Plug2 1 2 B
12. t 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 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 Use Giant recommended oil 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 Important Check torque bi weekly on item 49A 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 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 ob tained from the chart on page 3 6 Before beginning operation of your pumping system remember Check that the crankcase and seal areas have been properly lubricated per recommended
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