Giant Coffeemaker GP7150A User Manual

Triplex Ceramic  
Plunger Pump  
Operation Manual  
Models  
GP7150A and GP7155A  
Contents:  
Installation Instructions  
page 2  
Pump Specifications (GP7150A): page 3  
Exploded View:  
Parts List:  
page 4  
page 5  
Pump Specifications (GP7155A): page 6  
Kits/Torque Specifications:  
Maintenance Information:  
Repair Instructions:  
page 7  
page 7  
page 8  
Troubleshooting Guide:  
Dimensions:  
WarrantyInformation  
page 9  
page 10  
back page  
Updated 10/07  
Specifications  
Model GP7150A  
U.S................................(Metric)  
Volume .................................................................................... 54.5 GPM .....................(206 LPM)  
Discharge Pressure ................................................................ 1900 PSI .......................(131 bar)  
Speed ..............................................................................................................................700 RPM  
Inlet Pressure (maximum) ...................................................... 145 PSI .........................(10 bar)  
Plunger Diameter .................................................................... 1.97” .............................50mm  
Plunger Stroke ........................................................................ 1.89” .............................48mm  
Crankshaft Diameter .............................................................. 1.89” .............................48mm  
Key Width ............................................................................... 0.6” ...............................14mm  
Crankshaft Mounting ......................................................................................................Either side  
Shaft Rotation ......................................................................... Top of pulley towards manifold  
o
Temperature of Pumped Fluids ............................................... Up to 140 oF .................(60 C)  
Inlet Ports .......................................................................................................................(2) 2-1/2" NPT  
Discharge Ports ..............................................................................................................(2) 1-1/4" NPT  
Weight ..................................................................................... 455 lbs...........................(206 kg)  
Crankcase Oil Capacity .......................................................... 1.6 Gal. .........................(6.0 liter)  
Fluid End Material...........................................................................................................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  
HORSEPOWER INFORMATION  
Pulley selection and pump speed are based on a 1725 Horsepower ratings shown are the power require-  
RPM motor and "B" section belts. When selecting ments for the pump. Gas engine power outputs must  
desired GPM, allow for a ±5% tolerance on pumps be approximately twice the pump power requirements  
output due to variations in pulleys, belts and motors shown above.  
among manufacturers.  
1. Select GPM required, then select appropriate when selecting an electric motor as the power source.  
motor and pump pulley from the same line. To compute specific pump horsepower requirements,  
We recommend that a 1.1 service factor be specified  
2. The desired pressure is achieved by selecting the use the following formula:  
(GPH X PSI) / 1450 = HP  
correct nozzle size that corresponds with the pump  
GPM.  
GP7150A HORSEPOWER REQUIREMENTS  
RPM GPM 800 PSI 1000 PSI 1300 PSI 1500 PSI 1900 PSI  
300 23.4  
400 31.2  
500 38.9  
600 46.7  
700 54.5  
13.4  
17.8  
22.2  
26.7  
31.1  
16.7  
22.3  
27.8  
33.4  
38.9  
21.7  
29.0  
36.1  
43.4  
50.6  
25.1  
33.4  
41.7  
50.0  
58.4  
31.8  
42.3  
52.8  
63.4  
74.0  
3
Exploded View - GP7150A and GP7155A  
4
PARTS LIST - GP7150A and GP7155A  
ITEM PART  
07600  
1A 05313  
DESCRIPTION  
Crankcase  
HeadforOilDipstick  
O-Ring  
OilFillerPlugAssy.  
CrankcaseCover  
Gasket,CrankcaseCover  
OilDipStick  
O-Ring,DipStick  
HexagonScrew  
Spring Washer  
DrainPlug  
Gasket,DrainPlug  
BearingCover  
RadialShaftSeal  
O-Ring  
TaperRollerBearing  
FittingDisc(Shim)  
Shaft Protector  
Crankshaft  
QTY.  
1
1
1
1
1
1
1
1
12  
12  
3
2
2
2
2
2
1-5  
1
1
1
3
3
3
1
8
4
8
1
1
3
3
3
3
3
ITEM PART  
38A 13156  
38B 06258  
38B 07721  
38C 07635  
DESCRIPTION  
O-Ringfor38  
QTY.  
1
3
3
3
O-Ringfor38,GP7150A  
O-Ringfor38,GP7155A  
SupportRingforO-Ring,  
GP7150Aonly  
SealSleeve,GP7150A  
SealSleeve,GP7155A  
GroovedRing,GP7150A  
GroovedRing,GP7155A  
SupportDisc,GP7155only  
PressureSpring,GP7150A  
O-Ring,GP7155A  
V-Sleeve,GP7150A  
V-Sleeve,GP7155A  
PressureRing,GP7150A  
PressureRing,GP7155A  
Sleeve Support Ring,  
GP7150Aonly  
1B  
2
4
5
8
01009  
13000  
07601  
07602  
07603  
01009  
22706  
06725  
07109  
07182  
07607  
07608  
07184  
07610  
3
3
3
3
3
3
3
3
6
6
3
3
39  
39  
07795  
13157  
9
39A 07796  
39A 07723  
10  
11  
12  
13  
14  
15  
16  
20  
40  
41  
41  
42  
42  
43  
43  
44  
07797  
07636  
13158  
07638  
07711  
07639  
07712  
05318  
20A 07611  
21  
22  
23  
24  
25  
28  
30  
07612  
13405  
07614  
13182  
13183  
13184  
07619  
3
8
8
1
2
6
6
6
6
6
6
6
6
6
3
6
6
3
3
6
3
1
1
1
1
1
1
49  
13159  
Stud Bolt  
HexagonNut  
Key  
49A 13160  
50 07790  
50A 13162  
51 08288  
51A 08281  
51B 08282  
Connecting Rod Assy.  
Crosshead Assy.  
Crosshead Pin  
CoverPlate  
HexagonScrew  
Grommet  
Disc  
CoverPlate  
EyeBolt  
RadialShaftSeal  
SealRetainer  
O-Ring  
Circlip  
FittingDisc  
OilScraper  
Plunger Pipe Assy.  
(36A-D),GP7150A  
Plunger Pipe Assy.  
(36A-D),GP7155A  
Plunger Connection  
PlungerPipe,GP7150A  
PlungerPipe,GP7155A  
Tension Screw  
CopperRing  
ValveCasing,Bronze  
CylinderStud  
ValveAssembly(51A-51H)  
Spring Tension Cap  
ValveSpringGuide  
30A 07225-0100  
30B 13136  
30C 08280  
30D 13154  
51C 07732-0100 ValveSpring  
51D 13164  
51E 08283  
51F 07653  
51G 13166  
51H 07266  
ValvePlate  
ValveSeat  
O-Ring  
Support Ring  
31  
32  
33  
07623  
07624  
07626  
O-Ring  
33A 07627  
33B 07628  
33C 07249  
56  
13167  
ValveAdaptor  
O-Ringfor56,58  
Support Ring for 56A, 58A  
Support Ring  
O-Ring  
Tension Spring  
Plug,M64x2  
CopperRingfor12  
Plug,1-1/4NPT  
Plug,2-1/2NPT  
Disc For Crankshaft  
HexagonScrew  
Valve Tool (Not Shown)  
56A 07658  
56B 07635  
56C 13166  
56D 07653  
34  
36  
13137  
07630  
3
3
57  
58  
13173  
13170  
36  
07706  
3
3
3
3
3
3
3
3
59A 07661  
36A 07667  
36B 07793  
36B 07666  
36C 07664  
36D 07665  
60  
61  
66  
67  
12251  
05170  
13362  
13358  
07662  
38  
38  
07794  
13155  
SealCase,GP7150A  
SealCase,GP7155A  
5
Specifications  
Model GP7155A  
U.S................................(Metric)  
Volume .................................................................................... 65.8 GPM .....................(250 LPM)  
Discharge Pressure ................................................................ 1500 PSI .......................(100 bar)  
Speed ..............................................................................................................................700 RPM  
Inlet Pressure (maximum) ...................................................... 145 PSI .........................(10 bar)  
Plunger Diameter .................................................................... 2.17” .............................55mm  
Plunger Stroke ........................................................................ 2.0” ...............................52mm  
Crankshaft Diameter .............................................................. 1.9” ...............................48mm  
Key Width ............................................................................... 0.6” ...............................14mm  
Crankshaft Mounting ......................................................................................................Either side  
Shaft Rotation ......................................................................... Top of pulley towards manifold  
o
Temperature of Pumped Fluids ............................................... Up to 140 oF .................(60 C)  
Inlet Ports .......................................................................................................................(2) 2-1/2" NPT  
Discharge Ports ..............................................................................................................(2) 1-1/4" NPT  
Weight ..................................................................................... 455 lbs...........................(206 kg)  
Crankcase Oil Capacity .......................................................... 1.6 Gal. .........................(6.0 liter)  
Fluid End Material...........................................................................................................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  
HORSEPOWER INFORMATION  
Pulley selection and pump speed are based on a 1725 Horsepower ratings shown are the power require-  
RPM motor and "B" section belts. When selecting ments for the pump. Gas engine power outputs must  
desired GPM, allow for a ±5% tolerance on pumps be approximately twice the pump power requirements  
output due to variations in pulleys, belts and motors shown above.  
among manufacturers.  
1. Select GPM required, then select appropriate when selecting an electric motor as the power source.  
motor and pump pulley from the same line. To compute specific pump horsepower requirements,  
We recommend that a 1.1 service factor be specified  
2. The desired pressure is achieved by selecting the use the following formula:  
(GPH X PSI) / 1450 = HP  
correct nozzle size that corresponds with the pump  
GPM.  
GP7155A PULLESY SELECTION & HORESPOWER  
REQUIREMENTS  
RPM GPM 800 PSI 1000 PSI 1300 PSI 1500 PSI  
479 45.0  
531 49.9  
585 55.0  
638 60.0  
700 65.8  
25.7  
28.5  
31.4  
34.3  
37.6  
32.1  
35.6  
39.3  
42.9  
47.0  
41.8  
46.3  
51.1  
55.7  
61.1  
48.2  
53.5  
58.9  
64.3  
70.5  
6
REPAIR KITS - GP7150A and GP7155A  
Plunger Packing Kit - GP7150A  
Inlet Valve Kit - # 09614  
# 09526  
Item  
38A  
38B  
38C  
39A  
42  
Item  
51B  
51C  
51D  
51E  
Part #  
08282  
07732-0100 Valve Spring  
13164  
08283  
Description  
Valve Spring Guide 1  
Qty.  
Part #  
13156  
06258  
07635  
07796  
07638  
Description  
O-Ring  
O-Ring  
Support Ring  
Grooved Ring  
V-Sleeve  
Qty.  
3
3
3
3
1
1
1
2
2
1
2
2
ValvePlate  
Valve Seat  
O-Ring  
Support Ring  
O-Ring  
51F/56D 07653  
51G/56C 13166  
51H  
56A  
56B  
6
07266  
07658  
07635  
Plunger Packing Kit - GP7155A  
# 09220  
O-Ring  
Support Ring  
Item  
38A  
38B  
39A  
41  
Part #  
13156  
07721  
07723  
13158  
07711  
Description  
O-Ring  
O-Ring  
Grooved Ring  
Support Ring  
V-Sleeve  
Qty.  
3
3
3
3
Oil Seal Kit - # 09221  
Item  
32  
Part #  
07624  
07627  
Description  
Radial Shaft Seal  
O-Ring  
Qty.  
3
3
42  
6
33A  
GP7150A and GP7155A TORQUE SPECIFICATIONS  
Position  
24  
36A  
36C  
49A  
58  
Item#  
13182  
07667  
07664  
13160  
13170  
Description  
TorqueAmount  
30 ft.-lbs. (40 NM)  
33 ft.-lbs. (45 NM)  
30ft.-lbs. (40 NM)  
103 ft.-lbs. (140 NM)  
107 ft-lbs (145 NM)  
Connecting RodAssembly  
Plunger Connection  
Tension Screw  
Hexagon Nut  
Plug  
Preventative Maintenance Check-List & Recommended Spare Part List  
Check  
Daily  
Weekly 50hr  
Every  
Every  
Every  
500 hr  
1500 hr  
3000hrs  
Oil Level / Quality  
Oil Leaks  
Water Leaks  
Belts, Pulley  
Plumbing  
X
X
X
X
X
Recommended Spare Part  
X
Oil Change (p/n 01154)  
Plunger Packing Kits(1 kit/Pump)  
X
X
X
Oil Seal Kit ( 1 kit/Pump  
Valve Kit ( 1 kit/pump)  
X
7
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  
assembly, 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.-lbs. (145 NM).  
TO CHECK SEALSAND 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 & 39A) and O-rings. When replacing the plunger pipe (36B), tighten tension screws  
(36C) to 30 ft. lbs. (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 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 to drop.  
MOUNTINGVALVE 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. lbs. (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 & 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.-lbs. (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
PUMP SYSTEM MALFUNCTIONS  
MALFUNCTION  
CAUSE  
REMEDY  
The Pressure and/  
Worn packing seals  
Replace packing seals  
or the Delivery Drops  
Broken valve springs  
Belt slippage  
Worn or Damaged nozzle  
Fouled discharge valve  
Replace springs  
Tighten or Replace belt  
Replace nozzle  
Clean valve assembly  
Worn or Plugged relief valve on pump Clean, Reset, and Replace  
worn parts  
Cavitations  
Check suction lines on inlet  
of pump for restrictions  
Unloader  
Check for proper operation  
Water in Crankcase  
Noisy Operating  
High Humidity  
Worn Seals  
Reduce oil change intervals  
Replace seals  
Worn bearings  
Cavitation  
Replace bearings, Refill  
crankcase oil with recommended  
lubricant  
Check inlet lines for restrictions  
and/or proper sizing  
Rough/Pulsating  
Operation with  
Pressure Drop  
Worn packing  
Inlet restriction  
Accumulator pressure  
Replace packing  
Check system for stoppage  
air leaks, correctly sized  
inlet plumbing to pump  
Recharge/Replace accumulator  
Unloader  
Cavitation  
Check for proper operation  
Check inlet lines for restrictions  
and/or proper size  
Pump Pressure as  
Drop at gun Rated,  
Pressure  
Restricted discharge plumbing  
Re-size discharge plumbing to flow  
rate of pump  
Excessive  
Leakage  
Worn plungers  
Replace plungers  
Worn packing/seals  
Adjust or Replace packing seals  
Excessive vacuum  
Cracked plungers  
Reduce suction vacuum  
Replace plungers  
Inlet pressure too high  
Reduce inlet pressure  
High Crankcase  
Temperature  
Wrong Grade of Oil  
Giant oil is recommended  
Improper amount of oil in crankcase  
Adjust oil level to proper amount  
9
GP7150A and GP7155A Dimensions - Inches (mm)  
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:  
1. Defects caused by negligence or fault of the buyer or third party.  
2. Normal wear and tear to standard wear parts.  
3. Use of repair parts other than those manufactured or authorized by Giant.  
4. Improper use of the product as a component part.  
5. Changes or modifications made by the customer or third party.  
6. 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  
INCIDENTALANDCONSEQUENTIALDAMAGESDIRECTLYORINDIRECTLYARISINGFROMTHESALEORUSE  
OF THIS PRODUCT.  
THELIMITEDWARRANTYSETFORTHHEREINISINLIEUOFALLOTHERWARRANTIESORREPRESENTATION,  
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.  
10/07GP7150A_GP7155A.PMD  

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