Giant Coffeemaker GP7150A User's Manual
Contents
1. Bronze 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 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 GP7155A PULLESY SELECTION amp HORESPOWER REQUIREMENTS RPM GPM 800 PSI 1000 PSI 1300 PSI 1500 PSI 638 60 0 343 429 557 643 REPAIR KITS GP7150A and 7155 Plunger Packing Kit GP7150A Inlet Valve Kit 09614 09526 Item Part Description Qty Ttem Part Description Qty 51B 08282 Valve Spring Guide 1 38A 13156 O Ring 3 51C 07732 0100 Valve Spring 1 38B 06258 O Ring 3 51D 13164 Valve Plate 1 38 07635 Support Ring 32. Discharge Ports rar tte eee Crankcase Capacity eere Fluid End Material i ertt nees LUE imas Metric ee 54 5 GPM 206 LPM ents 1900 PSI 131 bar O 700 RPM mcm 145 PSI 10 bar een 1 89 1 89 48mm 0 6 eese TUI Either side secures Top of pulley towards manifold Up to 140 F 60 2 2 1 2 NPT M 2 1 1 4 455 lbs 206 kg 1 6 Gal 6 0 liter Bronze 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 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 requi
3. NPT Plug 2 1 2 NPT Disc For Crankshaft Hexagon Screw Valve Tool Not Shown OTY WwW DW WW WWW W RRR RE W Specifications Model GP7155A NES Inlet Pressure maximum seeeeeeer Plunger Diameter Plumper Stroke etre rrr Crankshaft Diameter iedseteseseseetbves et vient eee ds Key eae reir ttt D o EIE ERR ER REED RC Crankshaft Mounting Shaft Rotation eite cria e ete eere us Temperature of Pumped Fluids ssssss Inlet POrts ics terr tenere te E e RR rts i Discharge POfts Weie Dt Crankcase Oil Capacity bt tene Fluid End Material eerte ett eet eoe ens Metric 65 8 GPM 250 LPM 1500 PSI 100 bar 700 RPM iens 145 PSI 10 bar nmm WO AOM Either side Top of pulley towards manifold iens Up to 140 F 60 D E 2 2 1 2 NPT M 2 1 1 4 455 168 206 kg 1 6 Gal 6 0 liter
4. 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 NOTE Contact Giant Industries for Service School Information Phone 419 531 4600 Specifications Model GP7150A NS POCO M Inlet Pressure maximum Plunger Diameter iue ete ta reed ere erede Pl nget Stroke eere tt rr Crankshaft Diameter Key Width 4 5 WIRE E HERES Crankshaft Mounting eee Shalit Rotation ceci rien nem aga Temperature of Pumped 1 6 Inlet
5. 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 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 out the 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 1mm 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 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 MALFUNCTION The Pressure and or the Delivery Drops Water in Crankcase Noisy Operating Rough Pu
6. 51 08283 Valve Seat 1 39A 07796 Grooved Ring 3 51E 56D 07653 O Ring 2 42 07638 V Sleeve 6 51G 56C 13166 Support Ring 2 51 07266 O Ring 1 Plunger Packing GP7155A 56A 07658 O Ring 2 09220 56B 07635 Support Ring 2 Item Part Description Qty 38A 13156 O Ring 3 38B 07721 O Ring 3 Oil Seal Kit 09221 39A 07723 Grooved Ring 3 Item Part Description Qty 41 13158 Support Ring 3 32 07624 Radial Shaft Seal 3 42 07711 V Sleeve 6 33A 07627 O Ring 3 GP7150A and GP7155A TORQUE SPECIFICATIONS Position Item Description Torque Amount 24 13182 Connecting Rod Assembly 30 ft Ibs 40 NM 36A 07667 Plunger Connection 33 ft Ibs 45 NM 36C 07664 Tension Screw 30ft lbs 40 NM 49A 13160 Hexagon Nut 103 ft Ibs 140 NM 58 13170 Plug 107 ft Ibs 145 NM Preventative Maintenance Check List amp Recommended Spare Part List Check Daily Weekly 50 Every Every Every SO0hr 1500 3000hrs poe OilLevel Quaity EX P Water Leaks EX Bets Pulley PX Plumbing Recommended Spare Part Oil Change p n 01154 GP7150A and GP7155A 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 The o ring 51H can be removed with a bent piece of wire To disassemble valve assem
7. Models Triplex Ceramic Plunger Pump Operation Manual GP7150A and GP7155A Updated 10 07 Contents Installation Instructions Pump Specifications GP71504 Exploded View Parts List Pump Specifications GP7155A 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 bet
8. T 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 10 07 GP7150A_GP7155A PMD
9. ant oil is recommended Adjust oil level to proper amount Inches mm imensions GP7150A and GP7155A D 1dN Z i Z X P L X Lec 398vHO2SIQ Erg 06 ENS 158 65 5 2 1 66 22 v8 08 Pl 9Z 66 21 oc 316H Q3advl OIM 68 11 00 8 99v 56 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
10. bly screw out the valve seat 51E from the spring tension guide 51A Check the 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 cross 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 When replacing the plunger pipe 36B tighten tension screws 36C to 30 ft Ibs 40 NM Replace worn parts grease seals with Silicone before installing 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 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
11. lsating 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 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 Gi
12. rements 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 RPMTGPM 800 PSI 1000 PSIT1300 PSIT1500 PSI 1900 PST 600 46 7 267 334 434 500 634 Exploded View GP7150A and GP7155A 19 99 IIEM PART 1 07600 1 05313 IB 01009 2 13000 4 07601 5 07602 8 07603 9 01009 10 2270 0725 07109 B 07182 07607 15 07608 16 07184 20 07610 20 07611 21 07612 22 13405 23 07614 24 13182 25 13183 2 13184 30 07619 30A 072250100 30B 13136 30C 08280 30D 13154 31 07623 32 07624 33 07626 07627 33B 07628 33C 07249 34 13137 36 07630 07706 36A 07667 36B 07793 36B 07666 36C 07664 36D 07665 38 07794 38 13155 PARTS LIST 7150 and 7155 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 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 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 GP7150A Pl
13. unger Pipe Assy 36A D GP7155A Plunger Connection PlungerPipe GP7150A PlungerPipe GP7155A Tension Screw Copper Ring SealCase GP7150A SealCase GP7155A QTY f TD WWWW WW Ww Ww PART 38A 38B 38B 38C 39 39 39A 39A 41 41 4 4 43 43 40 49A 50A 51 51A 51B SIC 51 5IE SIF 51G 51H 56A 59A 61 67 13156 06258 07721 07635 07795 13157 07796 07723 07797 07636 13158 07638 07711 07639 07712 05318 13159 13160 07790 13162 08288 08281 08282 07732 0100 13164 08283 07653 13166 07266 13167 07658 07635 13166 07653 13173 13170 07661 12251 05170 13362 13358 07662 DESCRIPTION O Ring for 38 O Ring for38 GP7150A O Ring for38 GP7155A Support Ring for O Ring GP7150A only Seal Sleeve GP7 150A Seal Sleeve GP7 155A Grooved Ring GP7150A Grooved Ring GP7155A Support Disc GP7155 only Pressure Spring GP7150A O Ring GP7155A V Sleeve GP7150A V Sleeve GP7155A Pressure Ring GP7150A Pressure Ring GP7155A Sleeve Support Ring GP7150A only Stud Bolt Hexagon Nut Valve Casing Bronze Cylinder Stud Valve Assembly 51A 51H Spring Tension Cap ValveSpring Guide ValveSpring ValvePlate Valve Seat O Ring Support Ring O Ring 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
14. 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 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 GIAN
15. ween 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
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