Page 1
Models
GP7145 and GP7255A
Triplex Ceramic
Plunger Pump
Operation Manual
Updated 11/07
Contents:
Installation Instructions page 2
Pump Specifications (GP7145): page 3
Exploded View: page 4
Parts List: page 5
Pump Specifications (GP7255A): page 6
Kits/Torque Specifications: page 7
Maintenance Information: page 7
Repair Instructions: page 8
Troubleshooting Guide: page 9
Dimensions: page 10
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 140
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
o
F, it is important to
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
charts on pages 3 and 6.
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.
operation can be obtained from the
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 oil level is between the two lines on the oil
dipstick. DO NOT OVERFILL.
Use Giant Recommended Oil (p/n 01154), or the
equivalent to SAE 85-90W Industrial Grear Lube.
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
NOTE: Contact Giant Industries for Service School Information. Phone: (419)-531-4600.
2
Page 3
Specifications
Model GP7145
U.S................................(Metric)
V olume (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
T emperature of Pumped Fluids............................................... Up to 140
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
o
F .................(60 oC)
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
Pulley selection and pump speed are based on a 1725
RPM motor and "B" section belts. When selecting
desired GPM, allow for a ±5% tolerance on pumps
output due to variations in pulleys, belts and motors
among manufacturers.
1. Select GPM required, then select appropriate
motor and pump pulley from the same line.
2. The desired pressure is achieved by selecting the
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 10.9 13.6 20.4 27.1 40.7
400 25.3 14.5 18.1 27.1 36.2 54.3
500 31.7 18.1 22.6 33.9 45.2 67.9
600 38.0 21.7 27.1 40.7 54.3 81.4
750 47.5 27.1 33.9 50.9 67.9 101.8
789 50.0 28.6 35.7 53.5 71.4 107.1
947 60.0 34.3 42.9 64.3 85.7 128.6
HORSEPOWER INFORMATION
Horsepower ratings shown are the power requirements for the pump. Gas engine power outputs must
be approximately twice the pump power requirements
shown above.
We recommend that 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:
(GPH X PSI) / 1450 = HP
* Intermittent Duty Only!
3
Page 4
Exploded View - GP7145 and GP7255A
4
Page 5
PARTS LIST - GP7145 and GP7255A
ITEM PART DESCRIPTION QTY.
1 07600 Crankcase 1
1A 05313 Head for Oil Dipstick 1
1B 01009 O-Ring 1
2 13000 Oil Filler Plug Assy. 1
4 07601 Crankcase Cover 1
5 07602 Gasket, Crankcase
Cover 1
8 07603 Oil Dip Stick 1
9 01009 O-Ring, Dip Stick 1
10 22706 Hexagon Screw 1 2
11 06725 Spring Washer 12
12 07109 Drain Plug 3
13 07182 Gasket, Drain Plug 2
14 07607 Bearing Cover 2
15 07608 Radial Shaft Seal 2
16 07184 O-Ring 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 07225-0100 Hexagon Screw 8
30B 13136 Grommet 4
30C 08280 Disc 8
30D 13154 Cover Plate 1
31 07623 Eye Bolt 1
32 07624 Radial Shaft Seal 3
33 07626 Seal Retainer 3
33A 07627 O-Ring 3
33B 07628 Circlip 3
33C 07249 Fitting Disc 3
34 13137 Oil Scraper 3
36 06165 Plunger Pipe Assy.
(36A-D), GP7145 3
36 07706 Plunger Pipe Assy.
(36A-D), GP7255A 3
36A 07667 Plunger Connection 3
36B 05157 Plunger Pipe, GP7145 3
36B 07666 Plunger Pipe, GP7255A 3
36C 06166 Tension Screw, GP7145 3
36C 07664 Tension Screw, GP7255A 3
36D 07665 Copper Ring 3
38 06167 Seal Case, GP7145 3
ITEM PART DESCRIPTION QTY.
38 13155 Seal Case, GP7255A 3
38A 13156 O-Ring for 38 3
38B 06258 O-Ring for 38, GP7145 3
38B 07721 O-Ring for 38, GP7255A 3
39 06171 Seal Sleeve, GP7145 3
39 13157 Seal Sleeve, GP7255A 3
39A 13290 Grooved Ring, GP7145 3
39A 07723 Grooved Ring, GP7255A 3
40 07797 Support Disc, GP7255 only 3
41 13296 Support Ring, GP7145 3
41 13158 Support Ring, GP7255A 3
42 13294 V-Sleeve, GP7145 9
42 07711 V-Sleeve, GP7255A 6
43 13293 Pressure Ring, GP7145 3
43 07712 Pressure Ring, GP7255A 3
45 13297 Tension Spring, GP7145 only 3
49 13159 Stud Bolt 8
49A 13160 Hexagon Nut 8
50 07791 Valve Casing 1
50A 13162 Cylinder Stud 2
51 05274A Valve Assembly (51A-51F) 6
51A 13165A Spacer Pipe 6
51B 07732-0100 Valve Spring 6
51 C 05314 Valve Plate 6
51D 05136A Valve Seat 6
51E 07653 O-Ring 6
51F 13166 Support Ring 6
53 22610 Plug 3
56 13167 Valve Adaptor 3
56A 07658 O-Ring for 56, 58 6
56B 07635 Support Ring for 56A, 58A 6
56C 13166 Support Ring 3
56D 07653 O-Ring 3
57 13173 Tension Spring 6
58 13170 Plug, M64 x 2 3
59A 07661 Copper Ring for 12 1
60 12251 Plug, 1-1/4” NPT 1
61 05170 Plug, 2-1/2” NPT 1
66 13362 Disc For Crankshaft 1
67 13358 Hexagon Screw 1
07662 Valve Tool (Not Shown) 1
05210 Plunger Conversion Assy.
(36-45), GP7145 1
05211 Plunger Conversion Assy.,
(36-45), GP7255A 1
17204 Valve Casing Assembly,
(1x12/50-61 and 50A) 1
17212 Crankcase Assembly,
(2x12/1-34/49/49A/52A/66/67) 1
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Page 6
Specifications
Model GP7255A
U.S................................(Metric)
V olume (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
T emperature of Pumped Fluids............................................... Up to 140
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
o
F .................(60 oC)
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
Pulley selection and pump speed are based on a 1725
RPM motor and "B" section belts. When selecting
desired GPM, allow for a ±5% tolerance on pumps
output due to variations in pulleys, belts and motors
among manufacturers.
1. Select GPM required, then select appropriate
motor and pump pulley from the same line.
2. The desired pressure is achieved by selecting the
correct nozzle size that corresponds with the pump
GPM.
GP7255A PULLEY SELECTION & HORSEPOWER
REQUIREMENTS
RPM GPM 800 PSI 1000 PSI 1300 PSI 1500 PSI
479 45.0 25.7 32.1 41.8 48.2 64.3
531 49.9 28.5 35.6 46.3 53.5 71.3
585 55.0 31.4 39.3 51.1 58.9 78.6
638 60.0 34.3 42.9 55.7 64.3 85.7
700 65.8 37.6 47.0 61.1 70.5 94.0
851 80.0* 45.7 57.1 74.3 85.7 114.3
HORSEPOWER INFORMATION
Horsepower ratings shown are the power requirements for the pump. Gas engine power outputs must
be approximately twice the pump power requirements
shown above.
We recommend that 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:
(GPH X PSI) / 1450 = HP
2000 PSI
*
* Intermittent Duty Only!
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Repair Kits - GP7145 and GP7255A
Plunger Packing Kit - GP7145
# 09603
Item Part # Description Qty.
38A 13156 O-Ring 3
38B 06258 O-Ring 3
39A 13290 Grooved Ring 3
42 13294 V-Sleeve 9
Plunger Packing Kit - GP7255A
# 09220
Item Part # Description Qty.
38A 13156 O-Ring 3
38B 07721 O-Ring 3
39A 07723 Grooved Ring 3
41 13158 Support Ring 3
42 07711 V-Sleeve 6
Oil Seal Kit
# 09221
Item Part # Description Qty.
32 07624 Radial Shaft Seal 3
33A 07627 O-Ring 3
V alve Repair Kits
# 09604 - Pumps Mfg. between 3/07 and 10/07
Item Part # Description Qty.
51B 07732-0100 Valve Spring 1
51C 05314 V alve Plate 1
51D 05136 Valve Seat 1
51E/56D 07653 O-Ring 2
51F/56C 13166 Support Ring 2
56A 07658 O-Ring 2
56B 07635 Support Ring 2
# 09604A - Pumps Mfg. after 10/07
Item Part # Description Qty.
51B 07732-0100 Valve Spring 1
51C 05314 V alve Plate 1
51D 05136A Valve Seat 1
51E/56D 07653 O-Ring 2
51F/56C 13166 Support Ring 2
56A 07658 O-Ring 2
56B 07635 Support Ring 2
GP7145 and GP7255A Torque Specifications
Position Item# Description Torque Amount
24 13182 Connecting Rod Assembly 30 ft.-lbs. (40 NM)
36 C 06166/07664 Tension Screw 30ft.-lbs. (40 NM)
49A 13160 Hexagon Nut 103 ft.-lbs. (140 NM)
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 X
Oil Leaks X
W ater Leaks X
Belts, Pulley X
Plumbing X
Recommended Spare Part
Oil Change (p/n 01154) X X
Plunger Packing Kits(1 kit/Pump)
Oil Seal Kit ( 1 kit/Pump
V alve Kit ( 1 kit/pump)
X
X
X
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GP7145 and GP7255A Repair Instructions
TO CHECK VAL VES
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 . T o remove the valve adapter (56) and tension spring (57),
use a pullout tool size 5. T o 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 SEALS AND PLUNGER PIPE
Loosen nuts (49A) and remove pump head (50). Separate the plunger connection (36A) from the crosshead (25) by means of two open-end wrenches (size 22mm and 27mm). Pull seal sleeves (39) out of their
fittings in the crankcase (1). T ake 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 installing.
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.
MOUNTING VAL VE 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). T ighten nuts (49A) to 103 ft. lbs. (140 NM).
TO DISASSEMBLE GEAR
T ake 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 connecting 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 connecting rod and crankshaft (22). T ake 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. T ighten
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).
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Page 9
PUMP SYSTEM MALFUNCTIONS
y
Adj
MALFUNCTION CAUSE REMEDY
The Pressure and/
or the Deliver
Water in Crankcase High Humidity Reduce oil change intervals
Noisy Operating Worn bearings Replace bearings, Refill
crankcase oil with recommended
and/or proper sizing
Rough/Pulsating
Operation with
Pressure Drop
Drops
Worn packing seals Replace packing seals
Broken valve springs Replace springs
Belt slippage Tighten or Replac e belt
Worn or Damaged nozzle Replace nozzle
Fouled discharge valve 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
Worn Seals Replace seals
lubricant
Cavitation Check inlet lines for restrictions
Worn packing Replace packing
Inlet restriction Check system for stoppage
air leaks, correctly sized
inlet plumbing to pump
Accumulator pressure Recharge/Replace a ccumulator
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
ust or Replace packing seals
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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
to the return to Giant Industries of all products under warranty consideration. Call (419)-531-4600 or fax (419)-5316836 to obtain an R.G.A. number.
prior
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.
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.
www.giantpumps.com
11/07 GP7145_GP7255A.PMD
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