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Giant GP7145 User's Manual

1. HORSEPOWER INFORMATION Horsepower ratings shown are the power require ments for the pump Gas engine power outputs must be approximately twice the pump power requirements 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 PST 1450 HP GP7255A PULLEY SELECTION amp HORSEPOWER REQUIREMENTS RPM GPM 800 PSI 1000 PS 1300 PSI 1500 PSI 2000 PSI 638 60 0 343 429 557 643 857 ntermittent Duty Only 6 Repair Kits GP7145 and GP7255A ren nenn F Plunger Packing Kit GP7145 Valve Repair Kits 09603 Item Part Description Qty 09604 Pumps Mfg between 3 07 and 10 07 38A 13156 O Ring 3 Ttem Part Description 38B 06258 O Ring 3 51B 07732 0100 Valve Spring 39A 13290 Grooved Ring 3 51C 05314 Valve Plate 4 13294 V Sleeve 9 5ID 05136 Valve Seat 51E 56D 07653 O Ring Plunger Packing Kit GP7255A SLF S6C 13166 Support Ring 09220 56A 07658 O Ring Item Part Description Qty 56B 07635 Support Ring 38A 13156 O Ring 3 38B 07721 O Ring 3 09604A Pumps Mfg after 10 07 39A 07723 Grooved Ring 3 Item Part Description 41 13158 Support Ring 3 51B 07732 0100 Valve Spring 42 07711 V Sleeve 6 51C 05314 Valve Plate 5ID 05136A Valve Seat Oil Seal Kit 51E 56D 07653 O Ring 09221 51F 56C 13166 Support Ring Jtem Part Descriptio
2. Loosen inner hexagon screws on the connecting rods 24 Note Connecting rods are marked for identification Do not twist connecting rod halves Each connect ing rod is to be reinstalled in the same position and orientation on the crankshaft journals Push the connecting rod halves as far into the crosshead guide as possible Check the surfaces of connect ing rod and crankshaft 22 Take outthe bearing cover 14 to one side and push out crankshaft taking particular care that the connecting rod doesn t bend Re assemble in reverse order Regulate axial bearing clearance to a minimum of 0 1 mm and a maximum of 0 15mm by means of fitting discs 20A The crankshaft should turn easily and with little clearance Tighten screws 24 to 30 ft Ibs 40 NM Important The connecting rod has to be able to slightly move sidewise at the crankshaft journal Important Seal 32 must always be installed so that the seal lip on the inside diameter faces the oil Possible axial float of the seal retainer 33 should be compensated with the shims 33C 8 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 PUMP SYSTEM MALFUNCTIONS CAUSE Worn packing seals Broken valve springs Belt slippage Worn or Damaged nozzle Fouled discharge valve Worn or
3. Support Ring GP7255A V Sleeve GP7145 V Sleeve GP7255A Pressure Ring GP7145 Pressure Ring GP7255A Tension Spring GP7145 only Stud Bolt Hexagon Nut Valve Casing Cylinder Stud Valve Assembly 51A 51F Spacer Pipe ValveSpring ValvePlate ValveSeat O Ring Support Ring Plug Valve Adaptor O Ring for 56 58 Support Ring for 56A 58A Support Ring O Ring Tension Spring Plug M64x2 Copper Ring for 12 Plug 1 1 4 NPT Plug 2 1 2 NPT Disc For Crankshaft Hexagon Screw Valve Tool Not Shown Plunger Conversion Assy 36 45 GP7145 Plunger Conversion Assy 36 45 GP7255A Valve Casing Assembly 1x12 50 61 and50A Crankcase Assembly 2x 12 1 34 49 49 A 52A 66 67 DE E E E EE E E E ex Specifications Model GP7255A Volume Continuous eese Volume Intermittent eese Discharge Pressure Continuous eessss Discharge Pressure Intermittent Speed Continuous sess Speed Intermittent eee Inlet Pressure maximum eseeeee Plunger Diameters sortent dites cient tto Plunget Stroke ere teet eee Crankshaft Diameter essere Key Wadi om e Hn d UE ees Crankshaft Mounting eese Shaft ROCAUOM iiuei reote tte Eta eee eds Temperature of Pumped Fluids sss Inlet Ports 1 dee
4. 68 11 00 8 99v 6 O XBXPL AIM 10 11 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 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 specification
5. 750 RPM peed GNCermiitleNt c SEET COENE EE EEEE 947 RPM Inlet Pressure maximum sese 145 PSL iaeenene 10 bar Plunger Diamietetiue it ree ier eid T assets 45mm Plunger Stroke 1 nenne meth ete ri eerte iens 2 0 Lausanne nteeeitiee 52mm Cranks aft Diameter enorme riter nr e rer ER 1195 bases eet a dues 48mm Key Width mt on E eine nan OO cocos tes tenes 14mm i cu edi idiom Either side Shatt ROCAWUOM RR daa n aN Top of pulley towards manifold Temperature of Pumped Fluids esses Up to 140 F 60 C Inlet Ports t etienne dete coti e eerie EE Qua e eee eee ei eque eere eeu eR Gadetd decendhs 2 2 1 2 NPT Discharge Ports P M 2 1 1 4 NPT horn 455 lbs 4 206 kg Crankcase Oil Capacity essen 1 6 Gal eee 6 0 liter Pl id End Matetial inrer Oen RH e UM C POR Me HERE PH HIDE ELE Pe a ous Spheroidical Cast Iron 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 appro
6. Models Triplex Ceramic Plunger Pump Operation Manual GP7145 and GP7255A Updated 11 07 Contents Installation Instructions Pump Specifications GP7145 Exploded View Parts List Pump Specifications GP7255A Kits Torque Specifications Maintenance Information Repair Instructions Troubleshooting Guide Dimensions Warranty Information page 2 page 3 page 4 page 5 page 6 page 7 page 7 page 8 page 9 page 10 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 betwee
7. 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 of Oil Improper amount of oil in crankcase 9 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 Inches mm imensions GP7145 and GP7255A D LdN 2 1 Z X LdN P L X 137INI Lec 398vHO2SIQ Erg 06 ENS 58 65 S Zvl 66 ZZ v8 08 Pl 9Z b6 21 oc 316H Q3advl OIM
8. er 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 Crosshead Assy Crosshead Pin Cover Plate Hexagon Screw Grommet Disc Cover Plate Eye Bolt Radial Shaft Seal Seal Retainer O Ring Circlip Fitting Disc Oil Scraper Plunger Pipe Assy 36A D GP7145 Plunger Pipe Assy 36A D GP7255A Plunger Connection PlungerPipe GP7145 PlungerPipe GP7255A Tension Screw GP7145 Tension Screw GP7255A Copper Ring Seal Case GP7145 QTY 1 1 1 1 1 ren Q9 Q9 Q9 Q9 Q9 9 O0 4 00 Ut Q0 QU A T2 T2 I2 I2 I2 2 5 9 UJ O92 O9 O9 C9 C9 C9 O9 C9 ITEM 38 38A 38B 38B 39 39 39A 39A 40 41 41 42 42 43 43 45 49 49A 50 50A 51 51A 51B SIC 51D SIE SIF 53 56A 56B 56D 57 58 59A 61 67 PART 13155 13156 06258 07721 06171 13157 13290 07723 07797 13296 13158 13294 07711 13293 07712 13297 13159 13160 07791 13162 05274A 13165A 07732 0100 05314 05136A 07653 13166 22610 13167 07658 07635 13166 07653 13173 13170 07661 12251 05170 13362 13358 07662 05210 05211 17204 17212 DESCRIPTION Seal Case GP7255A O Ring for 38 O Ring for 38 GP7 145 O Ring for38 GP7255A Seal Sleeve GP7145 Seal Sleeve GP7255A Grooved Ring GP7145 GroovedRing GP7255A Support Disc GP7255 only Support Ring GP7145
9. n Qty 56A 07658 O Ring 32 07624 Radial Shaft Seal 3 56B 07635 Support Ring 33A 07627 O Ring 3 GP7145 and GP7255A Torque Specifications Position Item Description Torque Amount 24 13182 Connecting Rod Assembly 30 ft Ibs 40 NM 36C 06166 07664 Tension Screw 30ft Ibs 40 NM 49A 13160 Hexagon Nut 103 ft Ibs 140 NM 58 13170 Plug 107 ft lbs 145 NM Preventative Maintenance Check List amp Recommended Spare Part List Check Daily Weekly 50hr Every Every Every 500 hr 1500 hr 3000hrs poe OilLevel Quaity X OlLeks 0 X L L Watrleaks EX Bets Pulley PX Plumbing o X LT Recommended Spare Part eee Oil Change p n 01154 PT OX X GP7145 and GP7255A Repair Instructions TO CHECK VALVES Loosen plugs 58 take out tension spring 57 and then remove the complete valve assembly 51 with either a valve tool or an M16 hexagon screw To remove the valve adapter 56 and tension spring 57 use a pullout tool size 5 To disassemble valve assembly carefully hit the top of the valve plate 51C with a metal dowel and press the valve seat 51E out of the valve adapter 56 Check sealing surfaces and replace worn parts Check O rings and support rings Tighten plugs 58 to 107 ft Ibs 145 NM TO CHECK SEALS AND PLUNGER PIPE Loosen nuts 49A and remove pump head 50 Separate the plunger connection 36A from the cros
10. n 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 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 condi tions invalidates the warranty 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 or the equivalent to SAE 85 90W Industrial Grear Lube 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 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 obtained from the charts on pages 3 and 6 6 Before beginning operation of your pumping s
11. priate 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 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 requirements 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 GP7145 PULLEY SELECTION amp HORSEPOWER REQUIREMENTS RPM GPM 800 PSI 1000 PSI 1500 PSI 2000 PSI 3000 PSI 600 38 0 217 271 407 543 814 947 60 0 343 429 643 857 1286 ntermittent Duty Only 3 Exploded View GP7145 and GP7255A 30A 30B 30C 30D 31 32 33 33A 33B 33C 36A 36B 36B 36C 36C 36D 38 PART 07600 05313 01009 13000 07601 07602 07603 01009 22706 06725 07109 07182 07607 07608 07184 07610 07611 07612 13405 07614 13182 13183 13184 07619 07225 0100 13136 08280 13154 07623 07624 07626 07627 07628 07249 13137 06165 07706 07667 05157 07666 06166 07664 07665 06167 PARTS LIST GP7145 and GP7255A DESCRIPTION Crankcase Head for Oil Dipstick O Ring Oil Filler Plug Assy Crankcase Cover Gasket Crankcase Cover Oil Dip Stick O Ring Dip Stick Hexagon Screw Spring Wash
12. s head 25 by means of two open end wrenches size 22mm and 27mm Pull seal sleeves 39 out of their fittings in the crankcase 1 Take the seal case 38 out of the seal sleeve 39 Examine the plunger parts 36A 36D seals 42 amp 39A and O rings 38A amp 38B When replacing the plunger pipe 36B tighten tension screws 36C to 30 ft Ibs 40 NM Replace worn parts grease seals with Silicone before install ing 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 valve adapter 56 when the pump is being turned Seal life can be increased if the pre tensioning allows fora 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 38A amp 38B on the seal case 38 Clean surfaces of seal sleeves in gear box and sealing surfaces of valve casing 50 Push the valve casing carefully on the O rings of the seal case and centering studs 50A Tighten nuts 49A to 103 ft Ibs 140 NM TO DISASSEMBLE GEAR Take out plunger 36 and seal sleeves 39 as described above Drain the oil After removing the circlip ring 33B lever out seal retainer 33 with a screw driver Check seals 32 amp 33A and surfaces of crosshead 25 Remove the crankcase cover 4
13. s set forth in the Operations Manuals provided by Giant Industries Inc oosom 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 THELIMITED WARRANTY SET FORTHHEREIN IS IN LIEU OF ALLOTHER WARRANTIES OR REPRESENTATION 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 Phone 419 531 4600 FAX 419 531 6836 Copyright 2007 Giant Industries Inc www giantpumps com 11 07 GP7145_GP7255A PMD
14. tt eee ete eee eee eee b o and Discharge Ports etre rote trance bum Crankcase Oil Capacity eere Fluid End Material cccccccsccccessceceesseeeeesteeeeeeseeeenees US Metric siiin 65 8 GPM 250 LPM nara 80 GPMF 303 LPM anaes 1500 PSI 100 bar its 2000 PSI 140 bar mE CO 700 RPM ES 85 RPM m 145 PSI 10 bar ein Nels E E E DUM B 2 07 ceat ODUM Denan 1 9 esee Em amas 0 6 Idmm E eve xU etude e uut Either side Top of pulley towards manifold UN Up to 140 F 60 C ERAT 2 2 1 2 NPT ots 2 1 1 4 NPT 455 lbs 206 kg p 1 6 Gal 6 0 liter E E estt ta rdiet necu e ten Spheroidical Cast Iron 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 GPM
15. ystem 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 NOTE Contact Giant Industries for Service School Information Phone 419 531 4600 Specifications Model GP7145 LUE E Metric Volume Continuous iecit eti teorie etes 47 5 GPM 180 LPM Volume Intermittent eesessessseseeeeeeee enne 60 GPM suuuuuuses 227 LPM Discharge Pressure cvs oerte rre terrre eter enin ee 3000 PSI 207 bar Speed Contim bolls eerie oa ia re een ta ge ret FR ee aa eae v eeu era nto eire eden ha Pe re RE ere Cedo

Giant GP7145 User's Manual

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