Giant Water Pump GP7150A User Manual

Triplex Ceramic  
Plunger Pump Manual  
Models  
GP7150A, GP7155A, GP7255A  
Contents:  
Installation Instructions  
GP7155A/GP7255A:  
Pump Specifications:  
page 2  
page 3  
Parts List/Exploded View: pages 4-5  
Pump Specifications  
GP7150A:  
page 6  
Recommended Spare  
Parts List:  
page 7  
Repair Instructions:  
Dimensions:  
Warranty Information  
page 7  
back page  
back page  
Updated 03/06  
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Specifications  
Model GP7155A, GP7255A  
................................................................U.S. ........................ Metric  
Volume.................................................... 65.8 GPM .............. 250 LPM  
Discharge Pressure ................................. 1500 PSI ................. 100 Bar  
Speed ...................................................... 2000 PSI ................. 138 Bar  
Inlet Pressure ........................................................................... Up to 700 RPM  
Plunger Diameter ....................................2.17” ....................... 55mm  
Plunger Stroke ........................................2.05” ....................... 52mm  
Crankshaft Diameter............................... 1.89” ....................... 48mm  
Key Width............................................... 0.55” ....................... 14mm  
Crankshaft Mounting............................................................... Either side  
Shaft Rotation .......................................................................... Top of pulley towards manifold  
Max.Temperature of Pumped Fluids ...... 140 oF ..................... 60 oC  
Inlet Ports ................................................................................ (2) 2-1/2" NPT  
Discharge Ports........................................................................ (2) 1-1/4" NPT  
Weight.....................................................374 lbs. ................... 170 kg  
Crankcase Oil Capacity ..........................1.6 Gal. ................... 6.0 liters  
Fluid End Material GP7155A.................................................. Bronze  
Fluid End Material GP7255A.................................................. Nickle Plated Spheroidical Cast Iron  
Mechanical Effecency @ 700 RPM ........................................ 0.83  
Volumetric Effecency @ 700 RPM ......................................... 0.96  
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.  
GP7155A, GP7255A PULLEY SELECTION & HORSEPOWER  
REQUIREMENTS  
PUMP  
PULLEY PULLEY  
MOTOR  
RPM GPM 800 PSI 1000 PSI 1300 PSI 1500 PSI 2000 PSI  
12.75  
12.75  
12.75  
12.75  
12.75  
9.00  
9.75  
10.75  
11.70  
12.75  
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  
64.3  
71.3  
78.6  
85.7  
94.0  
3
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Exploded View - GP7150A/GP7155A/GP7255A  
4
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Spare Parts List - GP7150A/GP7155A/GP7255A  
ITEM  
1
2
4
5
8
9
10  
11  
12  
13  
14  
15  
16  
20  
20A  
21  
22  
PART  
07600  
13000  
07601  
07602  
07603  
01009  
13133  
13134  
07109  
07182  
07607  
07608  
07184  
07610  
07611  
07612  
13405  
07614  
13182  
13183  
13184  
07619  
07225-0100  
13136  
08280  
13154  
07623  
07624  
07625  
07626  
07627  
07628  
07249  
13137  
07706  
DESCRIPTION  
Crankcase  
QTY.  
1
ITEM  
38  
PART  
07794  
13156  
07721  
06258  
07635  
13157  
07795  
07723  
07796  
07797  
13158  
07636  
07711  
07638  
07712  
07639  
07637  
13159  
13160  
07790  
07791  
06628  
13162  
08288  
08281  
08282  
DESCRIPTION  
QTY.  
3
3
3
3
3
3
3
3
3
3
3
3
6
6
3
3
3
8
8
1
1
1
2
6
6
6
6
6
6
6
6
6
3
6
6
3
3
6
3
1
1
1
1
1
Seal Case (GP7150A)  
O-Ring  
O-Ring (GP7155A/GP7255A)  
O-Ring (GP7150A)  
Oil Filler Plug Assembly  
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  
1
1
1
1
38A  
38B  
38B  
38C  
39  
Support Ring (GP7150A Only)  
Seal Sleeve (GP7155A/GP7255A)  
Seal Sleeve (GP7150A)  
Compact Ring (GP7155A/GP7255A)  
Compact Ring (GP7150A)  
Support Disc (GP7155A/GP7255A)  
O-Ring (GP7155A/GP7255A)  
Tension Spring (GP7150A)  
V-Sleeve (GP7155A/GP7255A)  
V-Sleeve (GP7150A)  
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
39  
39A  
39A  
40*  
41  
41  
42  
42  
43  
43  
44  
49  
49A  
50  
50  
50  
Pressure Ring (GP7155A/GP7255A)  
Pressure Ring (GP7150A)  
Support Ring (GP7150A only)  
Stud Bolt  
23  
24  
25  
28  
Key  
Connecting Rod Assy.  
Crosshead Assy.  
Crosshead Pin  
Cover Plate  
Hexagon Screw  
Grommet  
Washer  
Cover Plate  
Eye Bolt  
Radial Shaft Seal  
Shaft Seal  
Hex Nut  
Valve Casing (GP7155A)  
Valve Casing (GP7255A)  
Valve Casing (GP7150A)  
Cylinder Stud  
Valve Assembly  
Spring Tension Cap  
30  
30A  
30B  
30C  
30D  
31  
32  
32A  
33  
33A  
33B  
33C  
34  
50A  
51  
51A  
51B  
51C  
51D  
51E  
51F  
51G  
51H  
56  
Valve Spring Guide  
07732-0100 Valve Spring  
13164  
08283  
07653  
13166  
07266  
13167  
07658  
07635  
13166  
07653  
13173  
13170  
07661  
12251  
12252  
13362  
13358  
Valve Plate  
Valve Seat  
O-Ring  
Support Ring  
O-Ring  
Seal Retainer  
O-Ring  
Circlip  
Fitting Disc  
3
Valve Adaptor  
O-Ring  
Oil Scraper  
3
56A  
56B  
56C  
56D  
57  
58  
59A  
60  
36  
Plunger Pipe Assy.  
(GP7155A/GP7255A) (36 A-D)  
Plunger Pipe Assy. (36A-D)  
Plunger Connection  
Plunger Pipe (50mm)  
Plunger Pipe (55mm)  
(GP7155A/GP7255A)  
Tension Screw  
Copper Ring  
Support Ring  
Support Ring  
O-Ring  
Tension Spring  
Plug  
Copper Ring  
Plug, 1-1/4” NPT  
Plug, 2-1/2” NPT  
Disc For Crankshaft  
Hexagon Screw  
3
3
3
3
36  
07630  
07667  
07793  
07666  
36A  
36B  
36B  
3
3
3
3
36C  
36D  
38  
07664  
07665  
13155  
61  
66  
67  
Seal Case (GP7155A/GP7255A)  
* This item may be removed to add a third v-sleeve.  
Plunger Packing Kit  
Valve Kit  
# 09606*  
# 09526 - GP7150A  
Item  
38A  
38B  
39A  
41  
Part #  
13156  
06258  
07796  
07636  
07638  
Description  
O-Ring  
O-Ring  
Compact Ring  
O-Ring  
V-Sleeve  
Qty.  
Item  
51B  
51C  
51D  
51E  
51F  
51G  
51H  
56A  
56B  
56C  
56D  
Part #  
Description  
Valve Spring Guide  
Valve Spring  
Valve Plate  
Valve Seat  
O-Ring  
Support Ring  
O-Ring  
O-Ring  
Qty.  
1
1
1
1
2
2
2
2
3
3
3
3
6
08282  
07732-0100  
13164  
08283  
07653  
13166  
07266  
07658  
07635  
13166  
07653  
42  
Plunger Packing Kit  
# 9220 - GP7155A & GP7255A  
Item  
38A  
38B  
39A  
41  
Part #  
13156  
07721  
07223  
13158  
07711  
Description  
O-Ring  
O-Ring  
Compact Ring  
O-Ring  
V-Sleeve  
Qty.  
Support Ring  
Support Ring  
O-Ring  
2
1
1
3
3
3
3
6
* Note: When ordering a valve kit for a pump produced  
prior to 11/03, order kit #09222, which replaces part  
08281 with p/n 13163. Kit 09222 does not require p/n  
08282.  
42  
Oil Seal Kit - # 09221  
Item  
32  
32A  
33A  
Part #  
07624  
07625  
07627  
Description  
Radial Shaft Seal  
Shaft Seal  
Qty.  
3
3
3
O-Ring  
5
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Specifications  
Model GP7150A  
................................................................ U.S. ........................ Metric  
Volume.................................................... 54.5 GPM .............. 206 LPM  
Discharge Pressure ................................. 1900 PSI ................. 131 Bar  
Speed ....................................................................................... 700 RPM  
Inlet Pressure .......................................... 140 PSI .................. 10 Bar  
Plunger Diameter.................................... 1.97” ...................... 50mm  
Plunger Stroke ........................................ 1.89” ...................... 48mm  
Crankshaft Diameter............................... 1.89” ...................... 48mm  
Key Width............................................... 0.55” ...................... 14mm  
Crankshaft Mounting............................................................... Either side  
Shaft Rotation .......................................................................... Top of pulley towards manifold  
Max.Temperature of Pumped Fluids ...... 140 oF .................... 60 oC  
Inlet Ports ................................................................................ (2) 2-1/2" NPT  
Discharge Ports........................................................................ (2) 1-1/4" NPT  
Weight.....................................................374 lbs. ................... 170 kg  
Crankcase Oil Capacity .......................... 1.6 Gal. ................... 6.0 liters  
Fluid End Material .................................................................. Bronze  
Mechanical Effecency @ 700 RPM ........................................ 0.83  
Volumetric Effecency @ 700 RPM ......................................... 0.96  
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.  
GP7150A PULLEY SELECTION & HORSEPOWER REQUIREMENTS  
PUMP  
PULLEY PULLEY  
MOTOR  
RPM GPM 800 PSI 1000 PSI 1300 PSI 1500 PSI 1900 PSI  
12.75  
12.75  
12.75  
12.75  
12.75  
5.75  
7.50  
9.25  
11.00  
12.75  
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  
6
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GP7150A, GP7155A, GP7255A REPAIR INSTRUCTIONS  
TO CHECK VALVES  
Lossen plugs (58), take out tension spring (57) and then remove the complete valve (51) with either a valve tool or an  
M16 hexagon screw. Remove valve adapter (56) and tension spring (57) with pull-out tool size 5. There is an O-ring  
(51G) under both the suction and the discharge valve each of which can be removed with a bent piece of wire.To  
disassemble valve hit the top of the valve plate (C) carefully with a bolt and press the valve seat (A) out of the spacer  
pipe (E). Check sealing surfaces and replace worn parts. Check O-rings and support rings.Tighten plugs (58) to 107 ft.  
lbs.  
TO CHECK SEALS AND PLUNGER PIPE  
Loosen nuts (49A) and remove pump head. Separate plunger connection (36A) from crosshead (25) by means of two  
open-end wrenches (size 22 and 27). Pull seal sleeves (39) out of their fittings in the crankcase.  
Take seal case (38) out of seal sleeve (39). Examine plunger parts (36A-36D), seals (42,39A) and O-rings.  
When replacing plunger pipe (36B), tighten tension screws (36C) to 30 ft. lbs.  
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 spacer pipe (51E) when the pump is being turned. Seal life  
can be increased if the pretensioning 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 on seal case (38). Clean surfaces of seal sleeves in gear box and sealing surfaces of  
valve casing. Push valve casing carefully on O-rings of seal case and centering studs (50A). Tighten nuts (49A) to 103  
ft. lbs.  
TO DISASSEMBLE GEAR  
Take out plunger and seal sleeves as described above. Drain oil. After removing the circleclip 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 inner hexagon screws on the connecting rods (24) and push con rod halves as far into the crosshead guide as  
possible.  
Note:  
Connecting rods are marked for identification. Do not twist con rod halves. Con rod is to be reinstalled  
in the same position on shaft journals.Check surfaces of connecing rod and crankshaft (22) take out  
bearing cover to one side and push out crankshaft taking particular care that the conrod doesn't gt bent.  
Note:  
Seal (32A) must always be installed so taht the seat up on the inside diameter faces the oil.  
Reassemble in revers order: Regulate axial bearing clearance minimum 0.1mm, maximum 0.15-by  
Preventative Maintenance Check-List & Recommended Spare Part List  
Check  
Daily  
Weekly 50hr  
Every  
500 hr  
Every  
1500 hr  
Every  
3000hrs  
Oil Level / Quality  
Oil Leaks  
Water Leaks  
Belts, Pulley  
Plumbing  
X
X
X
X
X
Recommended Spare Part  
Oil Change (p/n 01154)  
X
X
X
X
Plunger Packing Kits(1 kit/Pump)  
See page 5 for kit list  
Oil Seal Kit ( 1 kit/Pump  
See page 5 for kit list)  
Valve Assembly Kit ( 1 kit/pump)  
See page 5 for kit list  
X
7
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GP7150A, GP7155A, GP7255A SERIES DIMENSIONS - INCHES (mm)  
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.  
Liabilityunderthiswarrantyisonallnon-wearpartsandlimitedtothereplacementorrepairofthoseproductsreturned  
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.  
THE LIMITED WARRANTY SET FORTH HEREIN IS IN LIEU OF ALL OTHER WARRANTIES OR REPRESENTA-  
TION, EXPRESSORIMPLIED, INCLUDINGWITHOUTLIMITATIONANYWARRANTIESORMERCHANTABILITY  
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  
(419) 531-4600  
FAX (419) 531-6836  
Copyright 2006 Giant Industries, Inc.  
03/06 GP7150A, GP7155A, GP7255A.PM6  
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