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 140 F, it is important to
insure a positive head to the pump to prevent cavitation.
3. 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 shut-off
gun.
4. 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.
5. 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.
6. 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 GP7124A
Volume ........................................................................................................ Up to 12.7 GPM
Discharge Pressure .................................................................................... Up to 10000 PSI
1
Speed .......................................................................................................... Up to 750 RPM
Inlet Pressure .............................................................................................. Up to 90 PSI
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
GP7124A PARTS LIST
ITEMPARTDESCRIPTION QTY.
107600Crankcase1
213000Oil Filler Plug Assembly1
407601Crankcase Cover1
507602 Hexagon Screw1
807603Oil Dip Stick1
901009O-Ring, Dip Stick1
1013133Hexagon Screw12
1113134Spring Washer12
1207109Drain Plug2
1307182Gasket, Drain Plug2
1407607Bearing Cover2
1507608Radial Shaft Seal2
1607184O-Ring2
2007610Taper Roller Bearing2
20A07611Fitting Disc (Shim)1
2107612Shaft Protector1
ITEMPARTDESCRIPTION QTY.
3413137Flinger3
3613138Plunger3
3813408Stuffing Box3
3913409Seal Case3
39A07150O-Ring6
39B07683Support Ring6
4013400Grooved Seal3
4107718Support Ring3
4207685Packing3
4313410Teflon Support Ring3
4413238Circlip3
4913159Stud Bolt8
49A13160Nut8
5013411Valve Casing1
50A13162Cylinder Stud2
5113146Inlet Valve Assy.3
2213405Crankshaft1
2307614Key1
2413182Connecting Rod Assy.3
24A13406Fitting Screw6
24B13407Washer6
2513183Crosshead Assy.3
2813184Crosshead Pin3
3007619Cover Plate1
30A07225Hexagon Screw8
30B13136Grommet4
30C07622Washer8
30D13154Cover1
3107623Eye Bolt1
3207624Radial Shaft Seal3
32A07625Shaft Seal3
3307626Seal Retainer3
33A07627O-Ring3
51A07693Support Ring6
51B12055O-Ring6
51C13131Inlet Valve Seat3
51D13130Valve Plate6
51E07062Valve Spring6
51F13147Spacer Pipe6
5213148Discharge Valve Assy.3
52C13149Discharge Valve Seat3
5807699Plug3
58A07700O-Ring3
58B07701Support Ring3
58C07702Hexagon Screw12
5907703Plug3
59A07704Seal3
6012253Plug G 3/41
6112251Plug G 1-1/41
6613362Disc for Crankshaft1
33B07628Circlip3
6713358Hexagon Screw1
4
Exploded View - GP7124A
5
GP7124A 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
Lossen screws (58C), take plugs (58) out of valve casing with two screws. Take out complete valve (51)
using either tool (part #07662) or stud bolt. Valve seats (51C and 52C) are pressed out of spacer pipe
(51F) by hitting the valve plate (51D) with a bolt. Check surfaces of valve plate, valve seat, O-rings (51B,
58A) and replace worn parts.
CAUTION: When reassembling: The suction valve seat (51C) is 1mm smaller in diameter than the
discharge valve seat (52C). Suction valve seats are marked "S" and always have to be
installed first. Discharge valve seats are marked "P" and are always tobe installed on top of
suction valve. Plugs (58) are to be tensioned down evenly with screws (58C) and crosswise
at 210NM.
TO CHECK SEALS AND PLUNGER PIPE
Loosen nuts (49A) and remove pump head. Separate plunger (36) from crosshead (25) by means of two
open-end wrenches (size 22 and 27). Pull seal sleeves (38) out of their fittings in the crankcase. Take seal
case (39) out of seal sleeve (38). Take seal-pack (40-43) out of seal sleeve. After removing the circlip ring
(44) take seal-pack (43A-C) out of seal sleeve (38).
Examine plunger (36) and seals (40,42,43B).
When replacing plunger (36), tighten new plunger to 26 ft.lbs.
Replace worn parts; grease seals with Silicone before installing.
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.
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.
6
GP7124A REPAIR INSTRUCTIONS
MOUNTING VALVE CASING
Check O-rings (39A) and support rings (39B) on seal case (39). Clean surfaces of seal sleeves in gear box
and sealing surfaces of valve casing.
Push valve casing carefully onto O-rings of seal case and centering studs (50A). Tighten nuts (49A) to103
ft-lbs.
TO DISASSEMBLE GEAR
Take out plunger and seal sleeves as described above. Drain oil. After removing the circlip 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.
CAUTION: 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 connecting rod and crankshaft (22)
Take out bearing cover to one side and push out crankshaft taking particular care that the con rod doesn't
get bent.
CAUTION: Seal (32A) must always be installed so that the seal-lip on the inside diameter faces the oil.
Reassemble in reverse order: Regulate axial bearing clearance - minimum 0.1mm, maximum
0.15mm-by means of fitting disc (20A). Shaft should turn easily with little clearance. Tighten
inner hexagon screws to 30 ft.-lbs.
CAUTION: Connecting rod has tobe able to be slightly moved sidewise at the stroke journals.
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
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.
THE LIMITED WARRANTY SET FORTH HEREIN IS IN LIEU OF ALL OTHER WARRANTIES OR
REPRESENTATION, 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.
prior to the return to Giant Industries of all products
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 1998 Giant Industries, Inc.
5/98 GP7124A.PM6
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