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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