Giant GP7128 User's Manual
Contents
1. in 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 1s optional although recommended by Giant Industries Inc to further 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 200 hours or less de pending 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 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 schedules Do not run the2. Valve Assembly Kit 09520 AWWARwWAAE Item Part Description Qty Item Part Description 38A 12055 O Ring Seal Case 3 SIA 12056 Support Ring 38B 07693 Support Ring 3 SIB 07354 O Ring 38C 07354 O Ring 3 SIC 13131 Inlet Valve Seat 38D 12056 Support Ring 3 SID 13130 Valve Plate 39A 13228 Grooved Ring 3 SIE 07062 Valve Spring 42 13369 V Sleeve 6 52C 13149 Discharge Valve Seat 43 06862 Sleeve Support Ring 3 58A 07700 O Ring 58B 07693 Support Ring Oil Seal Kit 09225 Item Part Description Qty 32 07624 Radial Shaft Seal 3 32A 07625 Ring 3 33A 07627 O Ring 3 GP7128 Repair Instructions NOTE Alwaystake time to lubricate all metal and non metal parts witha 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 1 Lossen screws 58C take 2 Take out complete valve 3 Valve seats 51C and 52C plugs 58 out of valve cas assemblies 51 and 52 us are pressed out of spacer ing with two screws ing either tool part pipe SIF by hitting the 07662 or stud bolt valve plate 51D with a bolt 51E 51C 51B or 52C 5 When reassembling The 4 Check surfaces of valve plate valve seat O rings 51B 58A and suction valve seat 51C is replace worn parts Imm smaller in diameter than the discharge valve seat 52C Suction valve seats are marked S and always have to be installed first Discharge valve seats a
3. of Oil Improper amount of oil in crankcase PUMP SYSTEM MALFUNCTIONS REMEDY Replace packing seals Replace springs Tighten or Replace belt Replace nozzle Clean valve assembly Clean Reset and Replace worn parts Check suction lines on inlet of pump for restrictions Check for proper operation Reduce oil change intervals Replace seals Replace bearings Refill crankcase oil with recommended lubricant Check inlet lines for restrictions and or proper sizing Replace packing Check system for stoppage air leaks correctly sized inlet plumbing to pump Recharge Replace accumulator Check for proper operation Check inlet lines for restrictions and or proper size Re size discharge plumbing to flow rate of pump Replace plungers Adjust or Replace packing seals Reduce suction vacuum Replace plungers Reduce inlet pressure Giant oil is recommended Adjust oil level to proper amount Preventative Maintenance Check List amp Recommended Spare Parts List Check Daily Weekly 50hrs Every Every Every 500 hrs 1500 hrs 3000 hrs Oil Level Quality Oil Leaks Water Leaks Belts Pulley Plumbing Recommended Spare Parts oirChange I Galonpra SA PPX Plunger Packing Kits 1 kit pump Valve Assembly Kit 1 kit pump Oil Seal Kit 1 kit pump See page 5 for kit list 10 GP7128 Dimensions Inches mm 12 99 329 LL Si D LES USR AS D ele be al LL di pl 12 99 329 11 81 299 3 6
4. 6 92 22 99 583 2 x 3 4 BSP Outlet 5 55 140 12 58 471 S iz 6 50 165 c al e 58 2 x 1 1 4 BSP Inlet 10 24 260 27 17 690 GIANTINDUSTRIES 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 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 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
5. 8 PMD
6. Triplex Ceramic Plunger Pump Operating Instructions Repair and Service Manual Contents Installation Instructions page 2 Pump Specifications page 3 Exploded View page 4 Parts List Kits page 5 Repair and Service pages 6 8 Torque Specs page 8 Trouble Shooting Chart page 9 Recommended Spare Parts List page 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 restrictions that can cause cavitation Teflon tape should be used to seal all joints If pumps are to be operated at temperatures in excess of 140 F it is important to insure a positive head to the pump to prevent cavita tion 3 The discharge plumbing from the pump should be properly sized to the flow rate to prevent line pres sure 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
7. ain Plug 2 43A 05355 Spacer Ring 14 07607 Bearing Cover 2 45 07173 Tension Spring 15 07608 Radial Shaft Seal 2 49 13159 Stud Bolt 16 07184 O Ring Bearing cover 2 49A 13160 Hexagon Nut 20 07610 Taper Roller Bearing 2 50 06099 Valve Casing 20A 07611 Fitting Disc Shim 1 5 50A 13162 Cylinder Stud 21 07612 Shaft Protector 1 51 13146 Inlet Valve Assy 22 13405 Crankshaft l SIA 12056 Support Ring 23 07614 Key 1 51B 07354 O Ring 24 13182 Connecting Rod Assy 3 SIC 13131 Inlet Valve Seat 24A 07616 Fitting Screw 6 51D 13130 Valve Plate 24B 08041 Washer 6 SIE 07062 Valve Spring 25 13183 Crosshead Assy 3 SIF 13147 Spacer Pipe 28 13184 Crosshead Pin 3 S 13148 Discharge Valve Assy 30 07619 Cover Plate 1 57 06078 Compression Spring 30A 07250100 Hexagon Screw 8 52C 13149 Discharge Valve Seat 30B 13136 Grommet 4 58 07699 Plug 30C 08280 Disc 8 58A 07700 O Ring 30D 13154 Cover 1 58B 07693 Support Ring 31 07623 Eye Bolt 1 58C 07702 Hexagon Screw 32 07624 Radial Shaft Seal 3 59 07703 Plug 3 4 32A 07625 Compact Ring 2 59A 07704 Copper Ring for 59 33 07626 Seal Retainer 3 60 13150 Plug 3 4 BSP 33A 07627 O Ring for 33 3 6l 13151 Plug 1 1 4 BSP 33B 07628 Circlip for 33 3 66 13362 Disc for Crankshaft 33C 07249 Shim 67 13358 Hexagon Screw 34 13137 Flinger 3 07662 Tool for valve assembly 36 06427 Plunger 3 17212 Crankcase Assembly 38 05354 Seal Case 3 1 34 49 49A S0A 66 67 GP7128 Pump Repair Kits Plunger Packing Kit 09464
8. h out crankshaft taking particular care that the connecting rod 24 doesn t bend CAUTION Seal 32A must always be installed so that the seal lip on the inside diameter faces the oil 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 fitting screws 24A to 30 ft Ibs 40 NM CAUTION Connecting rod 24 has to be able to be slightly moved sidewise at the stroke journals GP7128 Torque Specifications Position ltem Description Torque Amount 24A 07616 Fitting Screw 30 ft lbs 40NM 36 07664 Tensioning Screw 33 ft Ibs 45NM 49A 13160 Nut 103 ft Ibs 140NM 58 07699 Plug 156 ft Ibs 210NM MALFUNCTION The Pressure and or the Delivery Drops Water in Crankcase Noisy Operating Rough Pulsating Operation with Pressure Drop Pump Pressure as Drop at gun Rated Pressure Excessive Leakage High Crankcase Temperature CAUSE Worn packing seals Broken valve springs Belt slippage Worn or Damaged nozzle Fouled discharge valve Worn or Plugged relief valve on pump Cavitations Unloader High Humidity Worn Seals Worn bearings Cavitation Worn packing Inlet restriction Accumulator pressure Unloader Cavitation Restricted discharge plumbing Worn plungers Worn packing seals Excessive vacuum Cracked plungers Inlet pressure too high Wrong Grade
9. 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 itis 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 GP7128 OR i 17 9 GPM osineen 67 7 Liters minute Discharge Pressure 3800 PSP eener 400 Bar CPTI SAGE See a da nn T 750 RPM Inlet Pressure maximum ccccceeeecceeeeseeeeees 4 35 to 145 PSI est 0 3 to 10 Bar PIC SE AG et vi dias assutenes D EAIA 28 mm Pl nger STORES PA EEO 52 mm Crankshaft Diameter 2 en E EE E 48 mm Key WIG ME DO 14 mm ET e E ger Either side SR E e Top of pulley towards manifold Temperature of Pumped Fluids 140 F neeeeeeeessssssssssss 60 C en Oe e E EEEE EE 2 1 1 4 BSP Discharge POS a de 2 3 4 BSP DS es CIEN 170 Kg Crankcase e LOCAL 2 6 Liter
10. re marked P and are al ways tobe installed on top of suction valve Plugs 58 are to be tensioned down evenly with screws 58C and crosswise at 156 ft lbs 6 Loosen nuts 49A 7 Remove pump head 210 NM GP7128 Repair Instructions 8 Separate plunger 36 from 9 Pull seal sleeves 39 out of crosshead 25 by means of their fittings in the crank one open end wrench case Take seal case 38 out of seal sleeve 39 10 If o rings 38A and 38C or support rings 38B and 38D are damaged replace with new parts Examine plunger 36 for wear 11 Take a thin screw driver and pry out the grooved ring 39A Note This seal 39A will not be reusable so replace with a new part For the seal pack 41 43A remove with either a socket wrench or use a screw driver to push against the rear lip of the pressure ring 41 or v sleeves 42 You will need to remove seals evenly out of the seal sleeve 39 Be careful not to score the sleeve or metal parts 41 amp 43 GP7128 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 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
11. s PT Ne ee Stainless Steel Volumetric Efficiency 700 RPM sise 89 Mechanical Efficiency 700 RPM uuu cc ceeeceeeessesesseeeceeeeeeeeeeeeeeeeaaaaaas 83 NOTES This specification for maximum pressure and maximum speed apply to intermittent duty When the pump is used for continuous duty and or with water warmer than 100 F these values must be reduced by 10 GP7128 HORSEPOWER REQUIREMENTS 3000 PSI 4000 PSI 5000 PSI 5800 PSI _600 14 3 30 6 40 9 511 59 2 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 requirements for the source 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 GP7128 Pump GP7128 PARTS LIST ITEM PART DESCRIPTION OTY ITEM PART DESCRIPTION 1 07600 Crankcase 1 38A 12055 O Ring Seal Case 2 13000 Oil Filler Plug Assembly l 38B 07693 Support Ring for 38A 4 07601 Crankcase Cover 1 38C 07354 O Ring for 39 5 07602 Seal for Cover 1 38D 12056 Support Ring for 38C 8 07603 Oil Dip Stick 1 39 06426 Seal Sleeve 9 01009 O Ring Dip Stick 39A 13228 Grooved Ring 10 22706 Inner Hexagon Screw 12 4 13417 Pressure Ring 11 06725 Spring Washer 12 42 13369 V Sleeve 12 07109 Drain Plug 2 B 06862 Sleeve Support Ring 13 07182 Gasket Dr
12. 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 Sr m e Sr Zei 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 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 WARRAN TIES OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE AND ALL SUCH WARRANTIES ARE HEREBY DISCLAIMED AND EXCLUDED BY THE MANUFACTURER 3 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 2007 Giant Industries Inc GP712
13. to drop MOUNTING VALVE CASING NOTE Replace worn parts grease seals with silicone before installing 12 Check O rings 38A and support rings 38B on seal case 38 Clean surfaces of seal sleeves in gear box and sealing surfaces of valve casing Reassemble seal sleeve 39 by placing plunger 36 in seal sleeve place pressure ring 41 v sleeves 42 sleeve support ring 43 and tension spring 45 over plunger 36 Place the seal case onto the seal sleeve and press into the crankcase making sure that the weep hole on the seal sleeve is facing down Tighten tensioning screw 36C for plunger onto crosshead 25 with an open end wrench to 33 ft lbs 45NM 13 Push valve casing carefully onto O rings of seal case and centering studs SOA Tighten nuts 49A tol03 ft lbs 140NM TO DISASSEMBLE GEAR 14 Take out plunger 36 and seal sleeves 39 as described above Drain oil 15 After removing the circlip ring 33B lever out seal retainer 33 with a screw driver Check seals 32 32A 33A and surfaces of crosshead 16 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 CAUTION Connecting rods are marked for identification Do not twist con rod halves Con Rod is to be reinstalled in the same position on shaft journals 17 Check surfaces of connecting rod and crankshaft 22 Take out bearing cover 14 to one side and pus
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