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,1-1/4”NPT
Plug,2-1/2”NPT
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
|