Giant GP7128 User Manual

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Page 1

Model GP7128

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/Kits page 5 Repair and Service: pages 6-8 Torque Specs: page 8 Trouble Shooting Chart: page 9 Recommended Spare Parts List: page 10 Dimensions: page 11 Warranty Information: back page

Page 2

INSTALLATION 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 1400 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 200 hours or less depending on operating conditions.

2. Pump operation must not exceed rated pressure, volume, or RPM. A pressure relief 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.

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Specifications Model GP7128

Flow .....................................................................17.9 GPM..................... 67.7 Liters/minute

Discharge Pressure ............................................. 5800 PSI

......................................

400 Bar

Crankshaft Speed ....................................................................................... 750 RPM

Inlet Pressure (maximum) ...................................-4.35 to 145 PSI ........... -0.3 to 10 Bar

Plunger Diameter.................................................1.1” ............................... 28 mm

Plunger Stroke .....................................................2.1”............................... 52 mm

Crankshaft Diameter ........................................... 1.9” ............................... 48 mm

Key Width............................................................0.6” ............................... 14 mm

Crankshaft Mounting .................................................................................. Either side

Shaft Rotation ................................................................................T op of pulley towards manifold

T emperature of Pumped Fluids............................140

F ...........................60 oC

Inlet Ports ...................................................................................................(2) 1-1/4" BSP

Discharge Ports .......................................................................................... (2) 3/4" BSP

Weight ..................................................................375 lbs. ......................... 170 Kg

Crankcase Oil Capacity .......................................1.6 Gal. .........................6 Liters

Fluid End Material....................................................................................... Stainless Steel

Volumetric Efficiency @ 700 RPM............................................................ 89%

Mechanical Efficiency @ 700 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.

NOTES:1This specification for maximum pressure and maximum speed apply to

intermittent duty. When the pump is used for continuous duty and/or with water warmer than 100oF, these values must be reduced by 10%.

GP7128 HORSEPOWER REQUIREMENTS

RPM GPM 3000 PSI 4000 PSI 5000 PSI 5800 PSI

300 7.2 15.4 20.6 25.7 29.8 400 9.5 20.4 27.1 33.9 39.4 550 13.1 28.1 37.4 46.8 54.3 600 14.3 30.6 40.9 51.1 59.2 650 15.5 33.2 44.3 55.4 64.2 700 16.7 35.8 47.7 59.6 69.2 750 17.9 38.4 51.1 63.9 74.2

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. T o compute specific pump horsepower requirements, use the following formula:

GPM X PSI 1400

= hp

Page 4

Exploded View - GP7128 Pump

Page 5

GP7128 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 Cover 1 8 07603 Oil Dip Stick 1 9 01009 O-Ring, Dip Stick 1 10 22706 Inner Hexagon Screw 12 11 06725 Spring Washer 12 12 07109 Drain Plug 2 13 07182 Gasket, Drain Plug 2 14 07607 Bearing Cover 2 15 07608 Radial Shaft Seal 2 16 07184 O-Ring, 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 24A 07616 Fitting Screw 6 24B 08041 Washer 6 25 13183 Crosshead Assy. 3 28 13184 Crosshead Pin 3 30 07619 Cover Plate 1 30A 07225-0100 Hexagon Screw 8 30B 13136 Grommet 4 30C 08280 Disc 8 30D 13154 Cover 1 31 07623 Eye Bolt 1 32 07624 Radial Shaft Seal 3 32A 07625 Compact Ring 3 33 07626 Seal Retainer 3 33A 07627 O-Ring for 33 3 33B 07628 Circlip for 33 3 33C 07249 Shim 3 34 13137 Flinger 3 36 06427 Plunger 3 38 05354 Seal Case 3

ITEM PART DESCRIPTION QTY.

38A 12055 O-Ring, Seal Case 3 38B 07693 Support Ring for 38A 3 38C 07354 O-Ring for 39 3 38D 12056 Support Ring for 38C 3 39 06426 Seal Sleeve 3 39A 13228 Grooved Ring 3 41 13417 Pressure Ring 3 42 13369 V-Sleeve 3 4 3 06862 Sleeve Support Ring 3 43A 05355 Spacer Ring 3 45 07173 Tension Spring 3 49 13159 Stud Bolt 8 49A 13160 Hexagon Nut 8 50 06099 Valve Casing 1 50A 13162 Cylinder Stud 2 51 13146 Inlet Valve Assy. 3 51A 12056 Support Ring 6 51B 07354 O-Ring 6 51C 13131 Inlet Valve Seat 3 51D 13130 Valve Plate 6 51E 07062 Valve Spring 6 51F 13147 Spacer Pipe 6 52 13148 Discharge Valve Assy. 3 57 06078 Compression Spring 3 52C 13149 Discharge Valve Seat 3 58 07699 Plug 3 58A 07700 O-Ring 3 58B 07693 Support Ring 3 58C 07702 Hexagon Screw 12 59 07703 Plug, 3/4" 3 59A 07704 Copper Ring for 59 3 60 13150 Plug, 3/4” BSP 1 61 13151 Plug, 1-1/4” BSP 1 66 13362 Disc for Crankshaft 1 67 13358 Hexagon Screw 1

07662 Tool for valve assembly 17212 Crankcase Assembly

(1-34/49/49A/50A/66/67)

Plunger Packing Kit - 09464

Item Part # Description Qty. 38A 12055 O-Ring, Seal Case 3 38B 07693 Support Ring 3 38C 07354 O-Ring 3 38D 12056 Support Ring 3 39A 13228 Grooved Ring 3 42 13369 V-Sleeve 6 43 06862 Sleeve Support Ring 3

Oil Seal Kit # 09225

Item Part # Description Qty. 32 07624 Radial Shaft Seal 3 32A 07625 Ring 3 33A 07627 O-Ring 3

GP7128 Pump Repair Kits

Valve Assembly Kit - #09520

Item Part # Description Qty. 51A 12056 Support Ring 6 51B 07354 O-Ring 6 51C 13131 Inlet Valve Seat 3 51D 13130 Valve Plate 6 51E 07062 Valve Spring 6 52C 13149 Discharge Valve Seat 3 58A 07700 O-Ring 3 58B 07693 Support Ring 6

Page 6

GP7128 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.

1. Lossen screws (58C), take

plugs (58) out of valve casing with two screws.

2. Take out complete valve

assemblies (51 and 52) using either tool (part #07662) or stud bolt.

51F 51E 51 C 51B 51A 51C or 52C

or 52C

4. Check surfaces of valve plate, valve seat, O-rings (51B, 58A) and

replace worn parts.

6. Loosen nuts (49A) 7. Remove pump head.

3. Valve seats (51C and 52C)

are pressed out of spacer pipe (51F) by hitting the valve plate (51D) with a bolt.

5. 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 156 ft-lbs. (210 NM).

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GP7128 Repair Instructions

8. Separate plunger (36) from

crosshead (25) by means of one open-end wrench.

38A 38B 38 38B 38A 36

38C

10. If o-rings (38A and 38C) or support rings (38B and 38D) are

38D

damaged, replace with new parts. Examine plunger (36) for wear.

9. Pull seal sleeves (39) out of

their fittings in the crankcase. Take seal case (38) out of seal sleeve (39).

39A 39 41 42 43 45

11. Take a thin screw driver and pry out the grooved ring (39A).

Note: This seal (39A) will not be reusable, so replace with a new part. For the seal-pack (41-43A), remove with either a

socket wrench or use a screw driver to push against the rear lip of the pressure ring (41) or v-sleeves (42). You will need to remove seals evenly out of the seal sleeve (39). Be careful not

to score the sleeve or metal parts (41 & 43).

Page 8

GP7128 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. 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.

MOUNTING VALVE CASING NOTE: Replace worn parts; grease seals with silicone before installing.

12. Check O-rings (38A) and support rings (38B) on seal case (38). Clean surfaces of seal sleeves in gear box and sealing surfaces of valve casing. Reassemble seal sleeve (39) by placing plunger (36) in seal sleeve; place pressure ring (41), v-sleeves (42), sleeve support ring (43), and tension spring (45) over plunger (36). Place the seal case onto the seal sleeve and press into the crankcase, making sure that the weep hole on the seal sleeve is facing down. Tighten tensioning screw (36C) for plunger onto crosshead (25) with an open end wrench to 33 ft-lbs. (45NM)

13 . Push valve casing carefully onto O-rings of seal case and centering studs (50A). Tighten nuts (49A)

to103 ft-lbs. (140NM).

TO DISASSEMBLE GEAR

14 . Take out plunger (36) and seal sleeves (39) as described above. Drain oil. 15 . After removing the circlip ring (33B), lever out seal retainer (33) with a screw driver. Check seals

(32,32A,33A) and surfaces of crosshead.

16 . 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.

17 . Check surfaces of connecting rod and crankshaft (22). Take out bearing cover (14) to one side and

push out crankshaft taking particular care that the connecting rod (24) doesn't bend.

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). The crankshaft (22) should turn easily with little clearance. Tighten fitting screws (24A) to 30 ft.-lbs. (40 NM)

CAUTION: Connecting rod (24) has to be able to be slightly moved sidewise at the stroke journals.

GP7128 Torque Specifications

Position Item# Description Torque Amount

24A 07616 Fitting Screw 30 ft-lbs. (40NM)

36 07664 Tensioning Screw 33 ft.-lbs. (45NM)

49A 13160 Nut 103 ft.-lbs.(140NM)

58 07699 Plug 156 ft.-lbs.(210NM)

Page 9

PUMP SYSTEM MALFUNCTIONS

MALFUNCTION CAUSE REMEDY

The Pressure and/ or the Delivery Drops

Water in Cran kcase High Humidit

Noisy Operating Worn bearings Replace bearings, Refill crankcase oil with recommended

and/or proper sizing

Rough/Pulsating Operation with Pressure Drop

Worn packing seals Replace packing seals

Broken valve springs Replace springs Belt slippage Tighten or Replace belt Worn or Damaged nozzle Replace nozzle Fouled discharge valve Clean valve ass embly Worn or Plugged relief valve on pump Clean , Reset, and Repl ace

worn parts

Cavitations Check suction lines on inlet

of pump for restrictions

Unloader Check for proper operation

Reduce oil change intervals

Worn Seals Replace seals

lubricant

Cavitation Check inlet lines for restrictions

Worn packing Replace packing

Inlet rest r i ction Check sy stem for stoppage

air leaks, correctly sized inlet plumbing to pump

Accumulator pressure Recharge/Replace accumulator

Pump Pressure as Drop at gun Rated, Pressure

Excessive Leakage

High Crankcase Temperature

Unloader Check for proper operation Cavitation Check inlet lines for restrictions

and/or proper size

Restricted discharge plumbing Re-size discharge plumbing to flow

rate of pump

Worn plungers Replace plungers

Worn packing/seals

Excessive vacuum Reduce suction vacuum Cracked plungers Replace plungers Inlet pressure too high Reduce inlet pressure

Wrong Grade of Oil Giant oil is recommended

Improper amount of oil in crankcase Adjust oil level to proper amount

djust or Replace packing seals

Page 10

Preventative Maintenance Check-List & Recommended Spare Parts List

Check Daily Weekly 50hrs Every Every Every

500 hrs 1500 hrs 3000 hrs

Oil Level/Quality X Oil Leaks X W ater Leaks X Belts, Pulley X Plumbing X

Recommended Spare Parts

Oil Change (1 Gallon) p/n 1154 X X Plunger Packing Kits (1 kit/pump) X

(See page 5 for kit list)

V alve Assembly Kit (1 kit/pump) X

(See page 5 for kit list) Oil Seal Kit (1 kit/pump) X (See page 5 for kit list)

Page 11

GP7128 Dimensions - Inches (mm)

Page 12

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 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.

GP7128.PMD