Triplex Ceramic
Plunger Pump
Operation Manual
Models
GP7145GB and GP7255AGB
pump with gearbox
Contents:
Installation and Safety Instructions
page 2
Pump Specifications (GP7145GB-2.4):
Exploded View:
page 3
page 4
Parts List:
page 5
Pump Specifications (GP7255AGB-2.4):
Kits/Torque Specifications:
Maintenance Information:
Repair Instructions:
Troubleshooting Guide:
Dimensions:
page 6
page 7
page 7
pages 8-9
page 10
page 11
back page
Updated 10/07
Warranty Information
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Specifications
Model GP7145GB -2.4
U.S. ...............................(Metric)
Volume (Continuous).............................................................. 47.5 GPM .....................(180 LPM)
Volume (Intermittent) ............................................................. 60 GPM* ......................(227 LPM)*
Discharge Pressure ................................................................. 3000 PSI .......................(207 bar)*
Speed (Continuous) ........................................................................................................750 RPM
Speed (Intermittent) ........................................................................................................947 RPM
Inlet Pressure (maximum) ...................................................... 145 PSI .........................(10 bar)
Plunger Diameter .................................................................... 1.77” .............................45mm
Plunger Stroke ........................................................................ 2.0” ...............................52mm
Crankshaft Diameter............................................................... 1.9” ...............................48mm
Key Width............................................................................... 0.6” ...............................14mm
Crankshaft Mounting ......................................................................................................Either side
Shaft Rotation .................................................................................................................See Instructions on page 2
Temperature of Pumped Fluids .............................................. Up to 140 oF..................(60 oC)
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..........................................................................................................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.
HORSEPOWER INFORMATION
Horsepower ratings shown are the power require-
ments for the pump. Gas engine power outputs must
be approximately twice the pump power require-
ments 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
GP7145GB-2.4 PULLEY SELECTION & HORSEPOWER
REQUIREMENTS
Input RPM RPM GPM 800 PSI 1000 PSI 1500 PSI 2000 PSI 3000 PSI*
720
960
300 19.0
400 25.3
500 31.7
600 38.0
750 47.5
789 50.0
947 60.0
10.9
14.5
18.1
21.7
27.1
28.6
34.3
13.6
18.1
22.6
27.1
33.9
35.7
42.9
20.4
27.1
33.9
40.7
50.9
53.6
64.3
27.1
36.2
45.2
54.3
67.9
71.4
85.7
40.7
54.3
67.9
1200
1440
1800
1894
2273
81.4
101.8
107.1
128.6
* Intermittent Duty Only!
3
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Exploded View - GP7145GB-2.4/GP7255AGB-2.4
4
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PARTS LIST - GP7145GB-2.4/GP7255AGB-2.4
ITEM PART
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
Flange for Gearbox
Radial Shaft Seal
O-Ring
Hexagon Socket Screw
O-Ring
Gear Seal
QTY.
1
ITEM PART
DESCRIPTION
QTY.
1
05324
05313
01009
13000
07601
07602
07603
01009
22706
06725
07109
07182
07607
05325
07608
05326
05327
07184
05328
07610
07611
07612
13405
07614
13182
13183
13184
07619
07225-0100
13136
08280
13154
07623
07624
07626
07627
07628
07249
13137
06165
39A
40
41
41
42
42
43
43
45
49
49A
50
50A
51
51A
51B
51C
51D
51E
51F
53
07723
07797
13296
13158
13294
07711
13293
07712
13297
13159
13160
07791
13162
05274
13165
Grooved Ring, GP7255A
Support Disc, GP7255 only
Support Ring, GP7145
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
3
3
3
3
9
6
3
3
1A
1B
2
4
5
8
9
10
11
12
13
14
14A
15
15A
15B
16
17
20
20A
21
22
23
24
25
28
30
30A
30B
30C
30D
31
32
33
33A
33B
33C
34
1
1
1
1
1
1
1
8
8
3
2
1
1
1
1
6
2
1
2
1-5
1
1
1
3
3
3
1
8
4
8
1
1
3
3
8
8
1
2
6
6
6
6
6
6
6
3
3
6
6
3
3
6
3
1
1
1
Valve Assembly (51A-51F)
Spacer Pipe
07732-0100 Valve Spring
05314
05136
07653
13166
22610
13167
07658
07635
13166
07653
13173
13170
07661
12251
05170
05344
05328
05329
05330
05331
05332
07008
05333
05334
05335
05336
13358
05337
05319
05338
05339
05340
13243
05341
05342
05343
Valve Plate
Valve Seat
O-Ring
Support Ring
Plug
Valve Adaptor
O-Ring for 56, 58
Support Ring for 56A, 58A
Support Ring
O-Ring
Tension Spring
Plug, M64 x 2
Copper Ring for 12
Plug, 1-1/4” NPT
Plug, 2-1/2” NPT
Taper Roller Bearing
Fitting Disc (Shim)
Shaft Protector
Crankshaft
56
56A
56B
56C
56D
57
58
59A
60
Key
Connecting Rod Assy.
Crosshead Assy.
Crosshead Pin
Cover Plate
Hexagon Screw
Grommet
Disc
Cover Plate
Eye Bolt
Radial Shaft Seal
Seal Retainer
61
Gearbox Assy, 2.4:1 (G1-G21) 1
G1
G2
G3
G4
G5
G6
G7
G8
Casing, Bottom
Casing, Top
Cylindrical Pin
Hexagon Screw
Washer
Hexagon Socket Screw
Spacer Ring
Fitting Key
1
1
2
8
6
6
2
1
1
1
1
1
2
2
2
1
1
2
2
2
3
3
3
3
O-Ring
Circlip
Fitting Disc
Oil Scraper
3
36
Plunger Pipe Assy.
(36A-D), GP7145
Plunger Pipe Assy.
(36A-D), GP7255A
Plunger Connection
Plunger Pipe, GP7145
Plunger Pipe, GP7255A
Tension Screw, GP7145
Tension Screw, GP7255A
Copper Ring
Seal Case, GP7145
Seal Case, GP7255A
O-Ring for 38
O-Ring for 38, GP7145
O-Ring for 38, GP7255A
Seal Sleeve, GP7145
Seal Sleeve, GP7255A
Grooved Ring, GP7145
3
G9
Cogwheel
36
07706
G10
G11
G12
G13
G15
G16
G17
G18
G19
G20
G21
Tension Disc
Hexagon Screw
Pinion
Ball Bearing
Fitting Disc
Fitting Disc
Shaft Seal Ring
Fitting Key
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
36A
36B
36B
36C
36C
36D
38
07667
05157
07666
06166
07664
07665
06167
13155
13156
06258
07721
06171
13157
13290
Washer
Screw Plug
Copper Ring
38
38A
38B
38B
39
39
39A
07662
05210
Valve Tool (Not Shown)
Plunger Conversion Assy.
(36-45), GP7145
Plunger Conversion Assy.,
(36-45), GP7255A
1
1
1
05211
5
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Specifications
Model GP7255AGB-2.4
U.S. ...............................(Metric)
Volume (Continuous).............................................................. 65.8 GPM .....................(250 LPM)
Volume (Intermittent) ............................................................. 80 GPM* ......................(303 LPM)*
Discharge Pressure (Continuous) ........................................... 1500 PSI .......................(100 bar)
Discharge Pressure (Intermittent) ........................................... 2000 PSI .......................(140 bar)*
Speed (Continuous) ........................................................................................................700 RPM
Speed (Intermittent) ........................................................................................................851 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 .................................................................................................................See Instructions on page 2
Temperature of Pumped Fluids .............................................. Up to 140 oF..................(60 oC)
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..........................................................................................................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
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 require-
output due to variations in pulleys, belts and motors ments 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,
2. The desired pressure is achieved by selecting the use the following formula:
We recommend that a 1.1 service factor be specified
(GPH X PSI) / 1450 = HP
correct nozzle size that corresponds with the pump
GPM.
GP7255AGB-2.4 PULLEY SELECTION & HORSEPOWER
REQUIREMENTS
RPM GPM 800 PSI 1000 PSI 1300 PSI 1500 PSI
2000 PSI*
Input RPM
1150
479 45.0
531 49.9
585 55.0
638 60.0
700 65.8
851 80.0*
25.7
28.5
31.4
34.3
37.6
45.7
32.1
35.6
39.3
42.9
47.0
57.1
41.8
46.3
51.1
55.7
61.1
74.3
48.2
53.5
58.9
64.3
70.5
85.7
64.3
71.3
78.6
85.7
94.0
114.3
1274
1404
1531
1680
2042
* Intermittent Duty Only!
6
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Repair Kits - GP7145GB-2.4 and GP7255AGB-2.4
Plunger Packing Kit - GP7145GB-2.4
Plunger Packing Kit - GP7255AGB-2.4
# 09603
Item
38A
38B
39A
42
# 09220
Item
38A
38B
39A
41
Part #
13156
06258
13290
13294
Description
O-Ring
O-Ring
Grooved Ring
V-Sleeve
Qty.
3
3
3
9
Part #
13156
07721
07723
13158
07711
Description
O-Ring
O-Ring
Grooved Ring
Support Ring
V-Sleeve
Qty.
3
3
3
3
42
6
Valve Repair Kit
# 09604
Oil Seal Kit
# 09221
Item
51B
51C
51D
51E/56D 07653
51F/56C 13166
Part #
Description
Qty.
1
1
1
2
2
2
2
Item
32
33A
Part #
07624
07627
Description
Radial Shaft Seal
O-Ring
Qty.
3
3
07732-0100 Valve Spring
05314
05136
Valve Plate
Valve Seat
O-Ring
Support Ring
O-Ring
56A
56B
07658
07635
Support Ring
GP7145GB-2.4 and GP7255AGB-2.4 Torque Specifications
Position
Item#
13182
Description
Connecting Rod Assembly
Torque Amount
30 ft.-lbs. (40 NM)
30ft.-lbs. (40 NM)
103 ft.-lbs. (140 NM)
107 ft-lbs (145 NM)
24
36C 06166/07664 Tension Screw
49A
58
13160
13170
Hexagon Nut
Plug
Preventative Maintenance Check-List & Recommended Spare Part List
Check
Daily
Weekly 50hr
Every
200 hr
Every
1500 hr
Every
3000hrs
Oil Level / Quality
Oil Leaks
Water Leaks
Belts, Pulley
Plumbing
X
X
X
X
X
Recommended Spare Part
X
Oil Change
Plunger Packing Kits(1 kit/Pump)
X
X
X
Oil Seal Kit ( 1 kit/Pump
Valve Kit ( 1 kit/pump)
X
7
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GP7145GB-2.4 and GP7255AGB-2.4 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.-lbs. (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 & 39A) and O-rings (38A & 38B). When replacing the plunger pipe
(36B), tighten tension screws (36C) to 30 ft. lbs. (40 NM). Replace worn parts; grease seals with Sili-
cone 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.
MOUNTING VALVE CASING
Check O-rings (38A & 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 center-
ing 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) .
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).
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 con-
necting 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. Take out the bearing cover
(14).
8
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GP7145GB-2.4 and GP7255AGB-2.4 Repair Instructions
TO DISMANTLE REDUCTION GEAR
Remove screws (G4). Using screwing two screws into the both thread bores, press off the gear cover
(G2). Remove screw (G11) and take off the spacer ring (G7) and tension disc (G10). Push the cogwheel
(G9) off the shaft by screwing two screws into both thread bores. Finally, take the crankshaft (22) out of
the crankcase by tapping it towards the bearing cover side using a rubber hammer.
Check the surfaces of connecting rods (24), crankshaft (22) and crossheads (25). Check the surfaces of
the crosshead guides in the crankcase for any unevenness.
Reassemble in reverse order. Regulate axial bearing clearance to a minimum of 0.1mm and a maximum
0.15mm by means of fitting discs (20A). Insert the crankshaft by passing it through on the bearing cover
side. Press in the outer bearing ring (20). The crankshaft should turn easily and with little clearance.
Fit the bearing cover (14) and 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.
Heat the ball bearings (G13) before pressing them onto the pinion (G12). Slightly press the cogwheel
(G9) onto the crankshaft, so that the pinion (G12) together with the bearing (G13) can still be inserted.
When mounting, place the pinion (G12) onto the cogwheel so that they correctly interlock. Carefully tap
the cogwheel and the pinion simultaneously onto the crankshaft and into the bearing seat.
Fit tension disc (G10), and spacer ring (G7) and tighten screw (G11) with Loctite.
Fit seal (17) on to the cylindrical pins (G3).
Push the gear cover (G2) carefully on to the bearing (G13). make sure the radial shaft seal (G17) does
not get damaged during fitting on to the pinion.
Important! Before putting into operation again, turn the reduction gear shaft by hand at least four full
turns to make sure that the gear is correctly aligned.
9
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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
10
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Dimensions - GP7145GB-2.4 and GP7255AGB-2.4 - Inches (mm)
11
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GIANT INDUSTRIES LIMITED WARRANTY
GiantIndustries,Inc.pumpsandaccessoriesarewarrantedbythemanufacturer
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. Theoperationofpumpsandoraccessoriesexceedingthespecifications
set forth in the Operations Manuals provided by Giant Industries, Inc.
Liabilityunderthiswarrantyisonallnon-wearpartsandlimitedtothereplacement
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.
Repairorreplacementofdefectiveproductsasprovidedisthesoleandexclusive
remedyprovidedhereunderandtheMANUFACTURERSHALLNOTBELIABLE
FOR FURTHER LOSS, DAMAGES, OR EXPENSES, INCLUDING INCIDEN-
TAL AND CONSEQUENTIAL DAMAGES DIRECTLY OR INDIRECTLY ARIS-
ING 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, INCLUD-
INGWITHOUTLIMITATIONANYWARRANTIESORMERCHANTABILITYOR
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
(419) 531-4600
FAX (419) 531-6836
Copyright 2007 Giant Industries, Inc.
10/07 GP7145GB_GP7255AGB.PMD
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