Giant GP7124A User's Manual
Contents
1. Description Torque Amount 10 13133 Hexagon Screw 30 ft Ibs 36 13138 Plunger 26 ft Ibs 49A 13160 Nut 103 ft Ibs GP7124A Dimensions Inches 26 38 den 12 99 begoen el 18 31 PASANET Li OUTLET i oO A ji pa pe 3 35 2403 15 ii IDN 2 x 1 1 4 MET GE i INLET 1 99 a 1 8905 DIA p E We engt GL lie 12 95 lt i 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 Ifthey 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 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 covere2. A REPAIR INSTRUCTIONS MOUNTING VALVE CASING Check O rings 39A and support rings 39B on seal case 39 Clean surfaces of seal sleeves in gear box and sealing surfaces of valve casing Push valve casing carefully onto O rings of seal case and centering studs SOA Tighten nuts 49A to103 ft lbs TO DISASSEMBLE GEAR Take out plunger and seal sleeves as described above Drain oil After removing the circlip 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 mner 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 Rodis to be reinstalled in the same position on shaft journals Check surfaces of connecting rod and crankshaft 22 Take out bearing cover to one side and push out crankshaft taking particular care that the con rod doesn t get bent 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 Shaft should turn easily with little clearance Tighten inner hexagon screws to 30 ft Ibs CAUTION Connecting rod has tobe able to be slightly moved sidewise at the stroke journals GP7124A TORQUE SPECIFICATIONS Position Item
3. AR PURPOSE AND ALL SUCH WARRANTIES ARE HEREBY DISCLAIMED AND EXCLUDED BY THE MANUFACTURER Phone 419 531 4600 FAX 419 531 6836 www giantoumps com Copyright 1998 Giant Industries Inc GIANT INDUSTRIES INC 900 N Westwood Ave P O Box 3187 Toledo Ohio 43607 5 98 GP7124A PM6
4. Triplex Ceramic Plunger Pump M O d CH Operating Instructions Repair and Service GP7124A Contents Installation Instructions page 2 Pump Specifications page 3 Parts List Exploded View pages 4 5 Repair amp Service pages 6 7 Torque Specifications page 7 Dimensions back page Warranty Information back page Updated 5 98 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 in the event of a blockage or the use of a shu
5. Y ke N N 2 pl 2 2 e p 1 1 1 1 3 6 6 3 3 1 8 4 8 1 1 3 3 3 3 3 PART 13137 13138 13408 13409 07150 07683 13400 07718 07685 13410 13238 13159 13160 13411 13162 13146 07693 12055 13131 13130 07062 13147 13148 13149 07699 07700 07701 07702 07703 07704 12253 12251 13362 13358 DESCRIPTION Flinger Plunger Stuffing Box Seal Case O Ring Support Ring Grooved Seal Support Ring Packing Teflon Support Ring Circhp Stud Bolt Nut Valve Casing Cylinder Stud Inlet Valve Assy Support Ring O Ring Inlet Valve Seat Valve Plate Valve Spring Spacer Pipe Discharge Valve Assy Discharge Valve Seat Plug O Ring Support Ring Hexagon Screw Plug Seal Plug G3 4 Plug G 1 1 4 Disc for Crankshaft Hexagon Screw Wee uanauaanunneeunnuuaaue eu B N Fa Fa WD LA Exploded View GP7124A GP7124A REPAIR INSTRUCTIONS NOTE Alwaystake time to lubricate all metal andnon 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 TO CHECK VALVES Lossen screws 58C take plugs 58 out of valve casing with two screws Take out complete valve 51 using either tool part 07662 or stud bolt Valve seats 51C and 52C are pressed out of spacer pipe 51F by hitting the valve plate 51D with a bolt Check surfaces of
6. d 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 oakwn 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 GA 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 THE LIMITED WARRANTY SET FORTH HEREIN IS IN LIEU OF ALL OTHER WARRANTIES OR REPRESENTATION EXPRESS ORIMPLIED INCLUDING WITHOUT LIMITATION ANY WARRAN TIES OR MERCHANTABILITY OR FITNESS FOR A PARTICUL
7. ill 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 GP7124A Up to 12 7 GPM Up to 10000 PSI Inlet Pressure Up to 90 PSP Plunger Diameter Plunger Stroke Crankshaft Diameter Key Width Crankshaft Mounting Either side Shaft Rotation Top of pulley towards manifold Temperature of Pumped Fluids Up to 140 F Inlet Ports 2 1 1 4 NPT Discharge Ports Crankcase Oil Capacity Fluid End Material Volumetric Efficiency 700 RPM Mechanical Efficiency 700 RPM 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 NOTES Intermittent Duty 10 1 GPM 10 000 PSI System Requirements No Unloader or Regulator allowed Must use a safety valve and dump g
8. t 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 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 with Giant Industries Inc pumps is optional although 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 unloader 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 the pump dry for extended periods of time Cavitation w
9. un Positive inlet pressures are recommended GP7124A HORSEPOWER REQUIRMENTS 3000 PSI 5000 PSI 6000 PSI 7250 PSI GPM 10000 PSI 10 1 71 4 FOR INTERMITTENT DUTYONLY MUST RUN PUMP WITHA DUMP GUNAND SAFETY VALVE AN UNLOADERAND REGULATOR MUSTNOT BE USED 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 h 1400 PART 07600 13000 07601 07602 07603 01009 13133 13134 07109 07182 07607 07608 07184 07610 07611 07612 13405 07614 13182 13406 13407 13183 13184 07619 07225 13136 07622 13154 07623 07624 07625 07626 07627 07628 GP7124A PARTS LIST DESCRIPTION Crankcase Oil Filler Plug Assembly Crankcase Cover Hexagon Screw Oil Dip Stick O Ring Dip Stick Hexagon Screw Spring Washer Drain Plug Gasket Drain Plug Bearing Cover Radial Shaft Seal O Ring Taper Roller Bearing Fitting Disc Shim Shaft Protector Crankshaft Key Connecting Rod Assy Fitting Screw Washer Crosshead Assy Crosshead Pin Cover Plate Hexagon Screw Grommet Washer Cover Eye Bolt Radial Shaft Seal Shaft Seal Seal Retainer O Ring Circlip QT
10. valve plate valve seat O rings 51B 58A and replace worn parts CAUTION Whenreassembling The suction valve seat 51C 1s 1mm 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 are marked P and are always tobe installed on top of suction valve Plugs 58 are to be tensioned down evenly with screws 58C and crosswise at 210NM TO CHECK SEALSAND PLUNGER PIPE Loosen nuts 49A and remove pump head Separate plunger 36 from crosshead 25 by means of two open end wrenches size 22 and 27 Pull seal sleeves 38 out of their fittings in the crankcase Take seal case 39 out of seal sleeve 38 Take seal pack 40 43 out of seal sleeve After removing the circlip ring 44 take seal pack 43A C out of seal sleeve 38 Examine plunger 36 and seals 40 42 43B When replacing plunger 36 tighten new plunger to 26 ft Ibs Replace worn parts grease seals with Silicone before installing CAUTION Don tloosen 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 lubrica tion and keeps the seals cool It is therefore not necessary to replace seals before the leak age becomes too heavy and causes output and operating pressure to drop GP7124
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