Triplex Ceramic
Plunger Pump
Operation Manual
Models
GP7145 and GP7255A
Contents:
Installation Instructions
Pump Specifications (GP7145):
Exploded View:
page 2
page 3
page 4
page 5
Parts List:
Pump Specifications (GP7255A): 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 11/07
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Specifications
Model GP7145
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 ......................................................................... 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...........................................................................................................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 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.
GP7145 PULLEY SELECTION & HORSEPOWER
REQUIREMENTS
RPM GPM 800 PSI 1000 PSI 1500 PSI 2000 PSI 3000 PSI*
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
53.5
64.3
27.1
36.2
45.2
54.3
67.9
71.4
85.7
40.7
54.3
67.9
81.4
101.8
107.1
128.6
* Intermittent Duty Only!
3
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Exploded View - GP7145 and GP7255A
4
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PARTS LIST - GP7145 and GP7255A
ITEM PART
DESCRIPTION
Crankcase
HeadforOilDipstick
O-Ring
OilFillerPlugAssy.
CrankcaseCover
Gasket,Crankcase
Cover
QTY.
ITEM PART
DESCRIPTION
SealCase,GP7255A
O-Ringfor38
QTY.
3
3
3
3
3
3
3
3
3
3
3
9
6
3
3
3
8
8
1
2
6
6
6
6
6
6
6
3
3
6
6
3
3
6
3
1
1
1
1
1
1
1
07600
05313
01009
13000
07601
07602
1
1
1
1
1
38
13155
13156
06258
07721
06171
13157
13290
07723
07797
13296
13158
13294
07711
13293
07712
13297
13159
13160
07791
13162
05274A
13165A
07732-0100
05314
05136A
07653
13166
22610
13167
1A
1B
2
4
5
38A
38B
38B
39
O-Ringfor38,GP7145
O-Ringfor38,GP7255A
SealSleeve,GP7145
SealSleeve,GP7255A
GroovedRing,GP7145
GroovedRing,GP7255A
SupportDisc,GP7255only
SupportRing,GP7145
SupportRing,GP7255A
V-Sleeve,GP7145
V-Sleeve,GP7255A
PressureRing,GP7145
PressureRing,GP7255A
TensionSpring,GP7145only
Stud Bolt
HexagonNut
ValveCasing
CylinderStud
ValveAssembly(51A-51F)
SpacerPipe
ValveSpring
ValvePlate
ValveSeat
O-Ring
39
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
39A
39A
40
41
41
42
42
43
43
45
49
49A
50
50A
51
51A
51B
51C
51D
51E
51F
53
8
9
10
11
12
13
14
15
16
20
20A
21
22
23
24
25
28
07603
01009
22706
06725
07109
07182
07607
07608
07184
07610
07611
07612
13405
07614
13182
13183
13184
07619
07225-0100
13136
08280
13154
07623
07624
07626
07627
07628
07249
13137
06165
OilDipStick
O-Ring,DipStick
HexagonScrew
Spring Washer
DrainPlug
Gasket,DrainPlug
BearingCover
RadialShaftSeal
O-Ring
TaperRollerBearing
FittingDisc(Shim)
Shaft Protector
Crankshaft
Key
Connecting Rod Assy.
Crosshead Assy.
Crosshead Pin
CoverPlate
HexagonScrew
Grommet
Disc
CoverPlate
EyeBolt
RadialShaftSeal
SealRetainer
30
30A
30B
30C
30D
31
32
33
33A
33B
33C
34
Support Ring
Plug
ValveAdaptor
O-Ringfor56,58
Support Ring for 56A, 58A
Support Ring
O-Ring
Tension Spring
56
56A
56B
56C
56D
57
58
59A
60
07658
07635
13166
07653
13173
13170
07661
12251
05170
13362
13358
07662
05210
O-Ring
Circlip
FittingDisc
OilScraper
3
3
3
Plug,M64x2
CopperRingfor12
Plug,1-1/4”NPT
Plug,2-1/2”NPT
Disc For Crankshaft
HexagonScrew
Valve Tool (Not Shown)
Plunger Conversion Assy.
(36-45),GP7145
Plunger Conversion Assy.,
(36-45),GP7255A
Valve Casing Assembly,
(1x12/50-61and50A)
Crankcase Assembly,
36
Plunger Pipe Assy.
(36A-D),GP7145
Plunger Pipe Assy.
(36A-D),GP7255A
Plunger Connection
PlungerPipe,GP7145
PlungerPipe,GP7255A
TensionScrew,GP7145
TensionScrew,GP7255A
CopperRing
3
61
66
67
36
07706
3
3
3
3
3
3
3
3
36A
36B
36B
36C
36C
36D
38
07667
05157
07666
06166
07664
07665
06167
1
1
1
05211
17204
17212
SealCase,GP7145
(2x12/1-34/49/49A/52A/66/67)
1
5
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Specifications
Model GP7255A
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 ......................................................................... 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...........................................................................................................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 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.
GP7255A PULLEY SELECTION & HORSEPOWER
REQUIREMENTS
RPM GPM 800 PSI 1000 PSI 1300 PSI 1500 PSI
2000 PSI*
64.3
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
71.3
78.6
85.7
94.0
114.3
* Intermittent Duty Only!
6
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Repair Kits - GP7145 and GP7255A
Plunger Packing Kit - GP7145
# 09603
Valve Repair Kits
Item
38A
38B
39A
42
Part #
13156
06258
13290
13294
Description
O-Ring
O-Ring
Grooved Ring
V-Sleeve
Qty.
3
3
3
9
# 09604 - Pumps Mfg. between 3/07 and 10/07
Item
51B
51C
51D
51E/56D
51F/56C
56A
Part #
07732-0100
05314
05136
07653
Description
Valve Spring
Valve Plate
Valve Seat
O-Ring
Qty.
1
1
1
2
Plunger Packing Kit - GP7255A
# 09220
13166
07658
Support Ring
O-Ring
2
2
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
56B
07635
Support Ring
2
# 09604A - Pumps Mfg. after 10/07
Item
51B
51C
Part #
07732-0100
05314
05136A
07653
13166
Description
Valve Spring
Valve Plate
Valve Seat
O-Ring
Support Ring
O-Ring
Support Ring
Qty.
1
1
1
2
2
2
2
42
6
51D
Oil Seal Kit
# 09221
Item
32
33A
51E/56D
51F/56C
56A
Part #
07624
07627
Description
Radial Shaft Seal
O-Ring
Qty.
3
3
07658
07635
56B
GP7145 and GP7255A Torque Specifications
Position
24
36C
Item#
13182
06166/07664
13160
Description
Connecting Rod Assembly
Tension Screw
TorqueAmount
30 ft.-lbs. (40 NM)
30ft.-lbs. (40 NM)
103 ft.-lbs. (140 NM)
49A
Hexagon Nut
58
13170
Plug
107 ft-lbs (145 NM)
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
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GP7145 and GP7255A 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 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 (38A & 38B). When replacing the plunger pipe (36B), tighten
tension screws (36C) to 30 ft. lbs. (40 NM). Replace worn parts; grease seals with Silicone before install-
ing.
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 (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 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
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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
9
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GP7145 and GP7255A Dimensions - Inches (mm)
10
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11
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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.
11/07GP7145_GP7255A.PMD
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