Model
GP7122
Triplex Ceramic
Plunger Pump
Operating Instructions/
Repair and Service
Manual
Contents:
Installation Instructions: page 2
Pump Specifications: page 3
Exploded View: page 4
Parts List: page 5
Kits: page 6
Torque Specifications: page 6
Repair Instructions: pages 7-10
Dimensions: page 11
Warranty Information: back page
INST ALLATION INSTRUCTIONS
Installation of the Giant Industries, Inc., pump is
not a complicated procedure, but there are some
basic steps common to all pumps. The following
information is to be considered as a general
outline for installation. If you have unique
requirements, please contact Giant Industries,
Inc. or your local distributor for assistance.
1. The pump should be installed flat on a base to a
maximum of a 15 degree angle of inclination to
ensure optimum lubrication.
2. The inlet to the pump should be sized for the
flow rate of the pump with no unnecessary restrictions that can cause cavitation. Teflon tape should
be used to seal all joints. If pumps are to be operated at temperatures in excess of 140o F, it is important to insure a positive head to the pump to prevent
cavitation.
IMPORTANT! To guarantee weep return, it is
essential that the inlet line is fitted to the support
screw (#62). If the inlet line is mounted to the
other side of the pump, then the whole connection
part (#s 62-62B, 64, 69-71) must be fitted to the
same inlet side.
3. A tube fitting on the side of the pumphead which
allows the circulation of water between the valve
casing and seal sleeves to take place. The tube fitting
must always be mounted on the same side as the
suction line.
4. The discharge plumbing from the pump should
be properly sized to the flow rate to prevent line
pressure loss to the work area. It is essential to
provide a safety bypass valve between the pump
and the work area to protect the pump from pressure
spikes in the event of a blockage or the use of a shutoff gun.
5. Use of a dampener is necessary to minimize
pulsation at drive elements, plumbing, connections, and other system areas. The use of a
dampener with Giant Industries, Inc. pumps is
optional, although recommended by Giant
Industries, Inc. to further reduce system pulsation. Dampeners can also reduce the severity of
pressure spikes that occur in systems using a
shut-off gun. A dampener must be positioned
downstream from the unloader.
6. Crankshaft rotation on Giant Industries, Inc.
pumps should be made in the direction designated by the arrows on the pump crankcase.
Reverse rotation may be safely achieved by
following a few guidelines available upon
request from Giant Industries, Inc. Required
horsepower for system operation can be obtained from the chart on page 3.
7 Before beginning operation of your pumping
system, remember: Check that the crankcase
and seal areas have been properly lubricated per
recommended schedules. Do not run the pump
dry for extended periods of time. Cavitation
will result in severe damage. Always remember
to check that all plumbing valves are open and
that pumped media can flow freely to the inlet of
the pump.
Finally, remember that high pressure
operation in a pump system has many
advantages. But, if it is used carelessly
and without regard to its potential
hazard, it can cause serious injury.
IMPORTANT OPERATING CONDITIONS
Failure to comply with any of these
conditions invalidates the warranty
1. Prior to initial operation, add oil to crankcase so
that the oil level is between the two lines on the oil
dipstick. DO NOT OVERFILL. SAE 80 Indus-
trial Gear oil may be used. Crankcase oil should
be changed after the first 50 hours of operation,
then at regular intervals of 500 hours or less depending on operating conditions.
2. Pump operation must not exceed rated
pressure, volume, or RPM.
device must be installed in the discharge of the
system.
3. Acids, alkalines, or abrasive fluids cannot be
pumped unless approval in writing is obtained
before operation from Giant Industries, Inc.
4. Run the pump dry approximately 10 seconds
to drain the water before exposure to freezing
temperatures.
A pressure relief
2
Specifications Model GP7122
30
26
23
0 500 600 700
RPM
NPSHR Chart
NPSHR(FT-HEAD) Viscosity = 1 Centipoise
Volume ........................................................................................................ Up to 9.9 GPM
Discharge Pressure ..................................................................................... Up to 10,000 PSI
Speed .......................................................................................................... Up to 750 RPM
Inlet Pressure .............................................................................................. Up to 90 PSI
Plunger Diameter ........................................................................................ 22mm
Plunger Stroke ............................................................................................ 48mm
Crankshaft Diameter................................................................................... 48mm
Key Width................................................................................................... 14mm
Crankshaft Mounting .................................................................................. Either side
Shaft Rotation ................................................................................ Top of pulley towards manifold
Temperature of Pumped Fluids .................................................................. Up to 140 oF
Inlet Ports ................................................................................................... (2) 1 1/4" BSP
Discharge Ports........................................................................................... (2) 3/4" BSP
Weight......................................................................................................... 374 lbs.
Crankcase Oil Capacity .............................................................................. 1.6 Gal.
Fluid End Material ..................................................................................... Stainless Steel
Volumetric Efficiency @ 750 RPM............................................................ 89%
Mechanical Efficiency @ 750 RPM........................................................... 83%
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.
1
Positive inlet pressures are recommended!
2
To convert to FNPT threads, add 13377-0100 (Adapter) and 13376-0100 (Seal)
3
To convert to FNPT threads, add 14081-0100 (Adapter) and 14082 (Seal)
1
2
3
System Requirements: No Unloader or Regulator allowed. Must use a safety valve and dump gun.
90
85
750 RPM
80
Decibels
75
70
0 2900 5800 8700 11,600
RPM GPM 3000 PSI 5000 PSI 6000 PSI 7250 PSI 10000 PSI
500 RPM
Pressure (PSI)
GP7122 HORSEPOWER REQUIREMENTS
300 4.0 8.6 14.3 17.1 20.7 28.6
400 5.3 11.4 18.9 22.7 27.4 37.9
550 7.3 15.6 26.1 31.3 37.8 52.1
600 7.9 16.9 28.2 33.9 40.9 56.4
650 8.6 18.4 30.7 36.9 44.5 61.4
700 9.2 19.7 32.9 39.4 47.6 65.7
750 9.9 21.2 35.4 42.4 51.3 70.7
90
85
80
Decibels
75
70
0 2900 5800 8700 11,600
Pressure (PSI)
HORSEPOWER RATINGS:
The rating shown are the power requirements for the
pump. Gas engine power outputs must be
approximately twice the pump power requirements
shown above.
We recommend a 1.1 service factor be specified
when selecting an electric motor as the power source.
To compute specific pump horsepower requirements,
use the following formula:
GPM X PSI
= hp
1400
3
Exploded View - GP7122
4
Must be on inlet connection
side. See note on pg. 2.
GP7122 PARTS LIST
ITEM PART DESCRIPTION QTY.
1 07600 Crankcase 1
2 13000 Oil Filler Plug Assembly 1
4 07601 Crankcase Cover 1
5 07602 Seal for Crankcase Cover 1
8 07603 Oil Dip Stick 1
9 06225 O-Ring, Dip Stick 1
10 13133 Hexagon Screw 12
11 13134 Spring Washer 12
12 07606 Drain Plug 5
13 07182 Gasket, Drain Plug 2
14 07607 Bearing Cover 2
15 07608 Radial Shaft Seal 2
16 07184 O-Ring for Bearing Cover 2
20 07610 Taper Roller Bearing 2
20A 07611 Fitting Disc (Shim) 1-5
21 07612 Shaft Protector 1
22 13405 Crankshaft 1
23 07614 Key 1
24 13182 Connecting Rod Assy. 3
25 13183 Crosshead Assy. 3
28 13184 Crosshead Pin 3
30 07619 Cover Plate 1
30A
30B 13136 Grommet 4
30C 07622 Disc 8
30D 13154 Cover 1
31 07623 Eye Bolt 1
32 07624 Radial Shaft Seal 3
32A 07625 Seal Ring 3
33 07626 Seal Retainer 3
33A 07627 O-Ring for Seal Retainer 3
33B 07628 Circlip for Seal Retainer 3
34 13137 Oil Scraper (Flinger) 3
36 06748 Plunger 3
38 06749 Seal Sleave 3
38A 22764 Serrated Pin 3
38B 06750 Leakage Gasket 3
38C 06751 O-Ring 3
39 06752 Seal Case 3
39A 07150 O-Ring 6
07225-0100
Hexagon Screw 8
ITEM PART DESCRIPTION QTY.
39B 06266 Support Ring 6
40 07338 Tension Spring 3
41 06753 Support Disc 3
42 06754 Spiral Ring (Packing) 6
43 06755 Support Ring 6
44 06756 Guide Ring 3
45 06757 Pressure Ring 3
46 13390 Seal Ring 3
47 06758 Spacer Disc 3
48 07690 Circlip 3
49 13159 Stud Bolt 8
49A 13160 Hexagon Nut 8
50 06759 Valve Casing 1
50A 13162 Centering Stud 2
51A 12056 Support Ring 6
51B 07354 O-Ring 6
51C 06760 Inlet Valve Seat 3
51D 06761 Valve Plate 6
51E 06762 Valve Spring 6
51F 06763 Spacer Pipe 6
52C 06764 Discharge Valve Seat 3
57 06078 Tension Spring 3
58 07699 Plug 3
58A 07700 O-Ring 3
58B 07693 Support Ring 3
58C 07702 Hexagon Screw 12
59A 07661 Copper Ring (Gasket) 3
60 13150 Plug 3/4 BSP 1
61 13151 Plug 1-1/4 BSP 1
62 06765 Connecting Screw 1
62A 06766 Connection Ring 1
62B 06767 Seal Ring 2
63 06589 Plug 1
64 07258-0100 Steel Ring 2
66 13362 Disc for Crankshaft 1
67 13358 Hexagon Screw 1
69 06588 Screw-in Connector 1
70 06768 Threaded Elbow 1
71 06769 Curved Leakage Pipe 1
07704 Valve Tool (not shown) 1
5
GP7122 REPAIR KITS
Plunger Packing Kit #09551
Item Part # Description Qty.
39A 07150 O-Ring 6
39B 06266 Support Ring 6
42 06754 Spiral Ring (Packing) 6
43 06755 Support Ring 6
44 06756 Guide Ring 3
46 13390 Seal Ring 3
Oil Seal Kit #09225
Item Part # Description Qty.
32 07624 Radial Shaft Seal 3
32A 07625 Seal Ring 3
33A 07627 O-Ring 3
Inlet Valve Assembly Kit #09552
Item Part # Description Qty.
51A 12056 Support Ring 1
51B 07354 O-Ring 1
51C 06760 Inlet Valve Seat 3
51D 06761 Valve Plate 6
51E 06762 Valve Spring 6
Discharge Valve Assembly Kit #09553
Item Part # Description Qty.
51A 12056 Support Ring 1
51B 07354 O-Ring 1
51D 06761 Valve Plate 1
51E 06762 Valve Spring 1
52C 06764 Discharge Valve Seat 1
GP7122 TORQUE SPECIFICATIONS
Position Item# Description Torque Amount
24 13406 Inner Hexagon Screw 30 (ft.-lbs.)
36 13138 Plunger 33 (ft.-lbs.)
49A 13160 Nut 103 (ft.-lbs.)
58C 07702 Hexagon Screw 155 (ft.-lbs.)
6
GP7122 REPAIR INSTRUCTIONS
NOTE: Always take time to lubricate all metal and non-metal parts with a light film of oil before reassembling. This
step will help ensure proper fit, at the same time protecting the pump non-metal parts (elastomers) from cutting and scoring.
TO CHECK VALVES
58B 58A 57
1) Lossen and remove screws
(58C) with a 24mm socket
wrench.
4) Take out valve assemblies
(52 & 51) using either tool
(part #07704) or a stud bolt.
2) T ake plugs (58) out of valve
casing (50) by tightening
screws (58C) against valve
3) Remove the compression
spring (57) O-Ring (58A)
and support ring (58B).
casing with two screws.
51C (Suction)
52C (Discharge)
5) Valve seats (51C and 52C) are pressed out of spacer pipe (51F)
by hitting the valve plate (51D) with a socket extention.
51E 51D 52C 51A 51B
6) Check surfaces of valve plate (51D), valve seat (51C or 52C),
o-rings (51A), and support rings (51B). Replace worn parts.
7
GP7122 REPAIR INSTRUCTIONS
Valve Seat identification markings
TO CHECK SEALS
7) When reassembling: The inlet valve seat (51C) is 1mm smaller in
diameter than the discharge valve seat (52C). Inlet valve seats are
marked "S" and always have to be installed first. Discharge valve
seats are marked "P" and are always to be installed on top of inlet
valve. Plugs (58) are to be tensioned down evenly with screws (58C)
and in crosswise pattern at 155 (ft.lbs.).
8) Loosen nuts (49A) with a
24mm socket wrench.
11) By gripping hex flats, separate plunger (36) from crosshead (25) by means of two
open-end wrenches (size
22mm and 27mm).
9) With a rubber mallet tap the
back of the valve casing (50)
and pull the valve casing off
the stud bolt (49).
12) Remove tension spring (40)
from seal retainer (38).
10) Remove cover plate (30)
with a 10mm socket wrench.
13) Pull seal sleeves (38) and
plungers (36) out of their
fittings in the crankcase
(1) using ring groove as a
guide.
8
GP7122 REPAIR INSTRUCTIONS
CAUTION: Don't loosen the 3 plunger (36) before the valve casing has been removed otherwise the
plunger (36) could hit against the spacer pipe (51F) when the pump is being turned.
38A
38 38C 38B
14) Remove circlip ring (48)
from seal sleeve (38). Remove spacer disc (47) and
seal ring (46) from seal
sleeve. Replace worn or
damaged parts.
45 44 43 42 43 42 41
16) Remove support disc (41) seal unit (42, 43, 44) and pressure ring
(45) of seal sleeve (38). Examine seals for signs of wear or cavi-
tation, and if necessary, replace.
36 33B 34 44
17) Examine plunger (36) for signs of wear or cavitation. If the
surface of the plunger is worn, screw out the plunger with a
27mm tool. Clean centering and front surface of crosshead
with plunger (25).Thread new plunger carefully through
oiled seals in seal sleave. Coat thread of new plunger lightly
with bonding agent (e.g., loctite).
15) Remove leakage gasket (38B) from serrated pin (38A) on the
seal sleave (38). Check o-ring (38C) for damage and replace if
necessary. IMPORTANT! The 3.2 mm (diameter bore of the leak-
age gasket (38B) must be inserted directly on the serated pin (38A)
of the seal sleeve (38). The leakage gasket must fit snugly to the
seal so that the bevelled surface of the gasket faces outwords.
NOTE: 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.
9
GP7122 REPAIR INSTRUCTIONS
TO ASSEMBLE VALVE CASING
18. Check O-rings (39A) and
support rings (39B) on seal
case (39). Clean surfaces of
seal sleeves (38) in crankcase
(1) and sealing surfaces of
valve casing (50). Insert seal
sleeve with plunger into
crankcase guide. Turn crankshaft to (22) until plunger with
crosshead (25) pushes against
plunger tighten plunger (36) to
26 ft-lbs.
19. Push valve casing carefully over O-rings of seal case and centering studs (50A). T ighten nuts (49A) to space
103 ft-lbs.
39A 39B 39 39B 3 9A
TO DISASSEMBLE GEAR END
20. Take out plunger (36) and seal sleeves (38) as described above. Drain oil.
21. After removing the circlip ring (33B), pry out seal adapter (33) with a screw driver
22. Check seals (32,32A,33A) and surfaces of plunger base (25).
23. Remove crankcase cover (4). Loosen inner hexagon screws (24A) on the connecting rods (24) and push
con rod halves as far into the crosshead guide as possible.
CAUTION: Connecting rods (24) are marked for identification. Do not twist connecting rod halves.
Connecting rod is to be reinstalled in the same position on crankshaft journals.
24. Check surfaces of the connecting rod (24) and crankshaft (22).
25. Take out bearing cover (14) to one side and push out crankshaft (22) taking particular care that the
connecting rod (24) doesn't bend.
CAUTION: Ring (32A) must always be installed so that the seal-lip on the inside diameter faces the oil.
26. Reassemble in reverse order: Regulate axial bearing clearance - minimum 0.1mm, maximum 0.15mm-by
means of fitting disc (20A). The crankshaft (22) should turn easily with little clearance. Tighten inner
hexagon screws (24A) to 30 ft.-lbs.
CAUTION: Connecting rod (24) has to be able to be slightly moved sidewise at the stroke journals.
27. Reassemble cover (4) and seal (5) onto crankcase (1). Fasten with hexagon screws (10).
28. Reinstall shim (33C), and seal adaptor (33) with radial shaft seal (32), ring (32A) and o-ring (33A) onto
crankcase (1).
29. Reinstall remainder of fluid end as described above in “To Assemble Valve Casing” section (21 and 22
above).
10
GP7122 Dimensions (Inches)
48kb
515
34093
312.5
330
165
141.5
300227
584
690
476.5
85 85.5
59
260
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 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 date of 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 manufacturers
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
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
REPRESENTATION, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION ANY WAR-
RANTIES OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE AND ALL SUCH
WARRANTIES ARE HEREBY DISCLAIMED AND EXCLUDED BY THE MANUFACTURER.
prior to the return to Giant Industries of all products under
GIANT INDUSTRIES, INC. 900 N. Westwood Ave., P.O. Box 3187, Toledo, Ohio 43607
Phone: (419)-531-4600 FAX (419)-531-6836, www.giantpumps.com
Ó Copyright 2001 Giant Industries, Inc.
9/01 GP7122.PM6
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