Giant Coffeemaker GP7155 5100 User Manual

Triplex Ceramic  
Plunger Pump Manual  
Model  
GP7155-5100  
Contents:  
Installation Instructions:  
Preventive Maintenance  
and Spare Parts List:  
Pump Specifications:  
Exploded View:  
Parts List/Kits:  
Repair Instructions:  
Dimensions:  
page 2  
page2  
page 3  
page 4  
page 5  
page 6  
page 7  
back page  
Warranty Information:  
Specifications - Model GP7155-5100  
U.S. ........................................... Metric  
Volume.............................................................................. 65.8 GPM .................................. 250 LPM  
Discharge Pressure ........................................................... 1500 PSI.................................... 100 Bar  
Crankshaft Speed.................................................................................................................. 700 RPM  
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  
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.  
GP7155-5100 PULLEY SELECTION &  
HORSEPOWER 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  
3
Exploded View - GP7155-5100  
4
Spare Parts List - GP7155-5100  
ITEM PART  
DESCRIPTION  
QTY.  
1
1
1
1
1
ITEM PART  
DESCRIPTION  
QTY.  
3
3
3
3
9
3
3
8
8
1
2
1
6
6
6
6
6
6
6
6
6
3
3
3
3
3
6
8
1
1
1
1
1
1
5
1
6
3
2
1
1
1
1
1
2
4
5
8
9
10  
07600  
13000  
07601  
07602  
07603  
01009  
13133  
Crankcase  
39B  
39C  
39D  
41  
07723-0100 Compact Ring  
07797-0100 Support Disc  
05218  
05219  
07711  
Oil Filler Plug Assembly  
Crankcase Cover  
Gasket, Crankcase Cover  
Oil Dip Stick  
Clip Ring  
Sleeve Support Ring  
V-Sleeve  
42  
O-Ring, Dip Stick  
Hexagon Screw  
07109-0400 Spring Washer  
1
43  
45  
49  
49A  
50  
50A  
50B  
51  
07712-0100 Pressure Ring  
12  
12  
3
2
2
2
2
05220  
13159  
06958  
Pressure Spring  
Stud Bolt  
Hex Nut  
11  
12  
13  
14  
15  
16  
20  
20A  
21  
07109  
07182  
07607  
07608  
07184  
07610  
07611  
07612  
13405  
07614  
13182  
Drain Plug  
Gasket, Drain Plug  
Bearing Cover  
Radial Shaft Seal  
O-Ring  
07790-5000 Valve Casing  
13162  
05221  
Cylinder Stud  
Discharge Casing  
08288-0100 Valve Assembly  
Taper Roller Bearing  
Fitting Disc (Shim)  
Shaft Protector  
Crankshaft  
2
1-5  
1
1
1
3
3
3
1
8
4
8
1
1
3
3
51A  
51B  
51C  
51D  
51E  
51F  
51G  
51H  
56  
56A  
56B  
56C  
56D  
57  
08281  
08282  
07732-0100  
13164-0100 Valve Plate  
08283 Valve Seat  
07653-0001 O-Ring  
13166  
06613  
05222  
07658  
07635  
13168  
07653  
13173  
05223  
Spring Tension Cap  
Valve Spring Guide  
Valve Spring  
22  
23  
24  
Key  
Connecting Rod Assy.  
13183-0100 Crosshead Assy.  
25  
28  
30  
30A  
30B  
30C  
30D  
31  
32  
32A  
Support Ring  
O-Ring  
13184  
07619  
07225-0100  
13136  
08280  
13154  
07623  
07624  
07625  
06950  
07627  
06951  
07249  
13137  
Crosshead Pin  
Cover Plate  
Hexagon Screw  
Grommet  
Valve Adaptor  
O-Ring for 56  
Support Ring for 56A  
Support Ring for 56D  
O-Ring  
Tension Spring  
Hexagon Screw  
Washer  
Cover Plate  
Eye Bolt  
Radial Shaft Seal  
Shaft Seal  
58  
59  
07109-0400 Plug, 1/2” BSP  
33  
Seal Retainer  
O-Ring  
3
3
3
59A  
60  
61  
06807 Steel Ring  
12251-0100 Plug, 1-1/4” BSP  
12252-0100 Plug, 2-1/2” BSP  
33A  
33B  
33C  
34  
Circlip  
Fitting Disc  
Oil Scraper  
07706-0100 Plunger Pipe Assy.  
3
3
3
3
66  
67  
68  
68A  
69  
13362  
13358  
06588  
06589  
Disc For Crankshaft  
Hexagon Screw  
Screw-in Connector  
36  
36A  
36B  
36C  
36D  
38  
38A  
38B  
39  
07667-0100 Plunger Connection  
Plug, 1/8” BSP  
07666  
Plunger Pipe  
3
07204-0100 Steel Ring  
07664-0100 Tension Screw  
07755-0100 Steel Ring  
13155-0100 Seal Case  
3
3
3
3
3
3
70  
71  
72  
73  
74  
75  
06768  
05224  
05225  
05226  
05227  
05228  
Threaded Elbow  
Elbow joint  
Curved leakage pipe  
Pipe Bend,180o  
Pipe Bend, 90o  
13156  
07721  
O-Ring  
O-Ring  
13157-0100 Seal Sleeve  
Straight leakage pipe  
Plunger Packing Kit - # 09609  
Valve Kit - # 09606  
Item Part #  
38A 13156  
38B 07721  
Description  
O-Ring  
O-Ring  
Qty.  
3
3
Item Part #  
Description  
Qty.  
1
1
51B 08282  
Valve Spring Guide  
51C 07732-0100 Valve Spring  
51D 13164-0100 Valve Plate  
42  
07711  
V-Sleeve  
9
1
51E  
51F  
08283  
07653-0001 O-Ring  
Valve Seat  
1
2
2
2
2
2
1
1
Oil Seal Kit - # 09221  
51G 13166  
51H 06613  
56A 07658  
56B 07635  
56C 13168  
56D 07653  
Support Ring  
O-Ring  
O-Ring  
Support Ring  
Support Ring  
O-Ring  
Item Part #  
Description  
Qty.  
3
3
32 07624  
32A 07625  
33A 07627  
Radial Shaft Seal  
Shaft Seal  
O-Ring  
3
5
GP7155-5100 REPAIR INSTRUCTIONS  
51C  
57  
51A 57  
58  
51  
56  
51E  
51D  
2. Remove valve adapter (56) and  
tension spring (57) with pull-out  
tool size 5. There is an O-ring  
To Check Valve Assemblies  
1. 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 Check Seals & Plungers.  
3.Loosen nuts (49A) and remove  
pump head. 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.  
(51G) under both the suction and  
the discharge valve each of which  
can be removed with a bent piece  
of wire.To disassemble unscrew the  
spring tension cap (51A) 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. Reinstall  
all parts in reverse order and  
tighten plugs (58) to 107 ft. lbs.  
39  
36B  
39A  
42  
43  
42  
38  
41  
4. 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.  
5. 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  
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 reverse order: Regulate axial bearing clearance minimum 0.1mm, maximum 0.15-by  
means of fitting disc (20A) shaft should yturn easily with little clearance. Tighten inner hexagon screws  
to 30 ft. lbs.  
Note:  
Connecting rod has to be able to be slighty moved sidewise at the stroke journals.  
6
GP7155-5100 Pump Dimensions - Inches (mm)  
7
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  
pumpparts, usedinportablepressurewashersandincarwashapplications, arewarrantedforfive  
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’sevaluationshowsweredefectiveatthetimeofshipmentbythemanufacturer. 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 INCIDENTAL AND CONSEQUENTIAL  
DAMAGES DIRECTLY OR INDIRECTLY ARISING FROM THE SALE OR USE OF THIS  
PRODUCT.  
THELIMITEDWARRANTYSETFORTHHEREINISINLIEUOFALLOTHERWARRAN-  
TIESORREPRESENTATION, EXPRESSORIMPLIED, INCLUDINGWITHOUTLIMITA-  
TIONANYWARRANTIESORMERCHANTABILITYORFITNESSFORAPARTICULAR  
PURPOSE AND ALL SUCH WARRANTIES ARE HEREBY DISCLAIMED AND EX-  
CLUDED 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.  
08/06 GP7155-5100.PMD  

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