Giant GP7150A User manual

Contents:
Installation Instructions
GP7155A/GP7255A: page 2
Pump Specifications: page 3
Parts List/Exploded View: pages 4-5
Pump Specifications
GP7150A: page 6
Recommended Spare
Parts List: page 7
Repair Instructions: page 7
Dimensions: back page
Warranty Information back page
Triplex Ceramic
Plunger Pump Manual
Models
GP7150A, GP7155A, GP7255A
Updated 03/06

2
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 restric-
tions that can cause cavitation. Teflon tape should
be used to seal all joints. If pumps are to be oper-
ated at temperatures in excess of 140oF, it is impor-
tant 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
INSTALLATION INSTRUCTIONS
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.
IMPORTANT OPERATING CONDITIONS
Failure to comply with any of these condi-
tions 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), which is equiva-
lent to SAE 85-90W Industrial Grear Lube. Crank-
case oil should be changed after the first 50 hours
of operation, then at regular intervals of 500 hours
or less depending on operating conditions.
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 un-
loader.
5. Crankshaft rotation on Giant Industries, Inc.
pumps should be made in the direction desig-
nated 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 charts on pages 3 & 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.
Finally, remember that high pres
sure operation in a pump system has many
advantages. But, ifit is used carelessly
and without regard to its potential hazard,
it can cause serious injury.
NOTE: Contact Giant Industries for Service School Information. Phone: [phone].

3
Specifications
Model GP7155A, GP7255A
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.
PUMP
PULLEY MOTOR PULLEY RPM GPM 800 PSI 1000 PSI 1300 PSI 1500 PSI 2000 PSI
12.75 9.00 479 45.0 25.7 32.1 41.8 48.2 64.3
12.75 9.75 531 49.9 28.5 35.6 46.3 53.5 71.3
12.75 10.75 585 55.0 31.4 39.3 51.1 58.9 78.6
12.75 11.70 638 60.0 34.3 42.9 55.7 64.3 85.7
12.75 12.75 700 65.8 37.6 47.0 61.1 70.5 94.0
GP7155A, GP7255A PULLEY SELECTION & HORSEPOWER
REQUIREMENTS
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.
HORSEPOWER INFORMATION
Horsepower ratings shown are the power require-
ments for the pump. Gas engine power outputs must
be approximately twice the pump power require-
ments 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
................................................................U.S. ........................ Metric
Volume.................................................... 65.8 GPM .............. 250 LPM
Discharge Pressure .................................1500 PSI................. 100 Bar
Speed ......................................................2000 PSI ................. 138 Bar
Inlet Pressure ........................................................................... Up to 700 RPM
Plunger Diameter....................................2.17”....................... 55mm
Plunger Stroke ........................................2.05” ....................... 52mm
Crankshaft Diameter...............................1.89”....................... 48mm
Key Width...............................................0.55” ....................... 14mm
Crankshaft Mounting............................................................... Either side
Shaft Rotation.......................................................................... Top of pulley towards manifold
Max.Temperature of Pumped Fluids ......140 oF ..................... 60 oC
Inlet Ports ................................................................................ (2) 2-1/2" NPT
Discharge Ports........................................................................ (2) 1-1/4" NPT
Weight.....................................................374 lbs. ................... 170 kg
Crankcase Oil Capacity ..........................1.6 Gal.................... 6.0 liters
Fluid End Material GP7155A.................................................. Bronze
Fluid End Material GP7255A.................................................. Nickle Plated Spheroidical Cast Iron
Mechanical Effecency @ 700 RPM ........................................ 0.83
Volumetric Effecency @ 700 RPM ......................................... 0.96

4
Exploded View - GP7150A/GP7155A/GP7255A

ITEM PART DESCRIPTION QTY.
1 07600 Crankcase 1
2 13000 Oil Filler Plug Assembly 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 13133 Hexagon Screw 12
11 13134 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 Washer 8
30D 13154 Cover Plate 1
31 07623 Eye Bolt 1
32 07624 Radial Shaft Seal 3
32A 07625 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 07706 Plunger Pipe Assy.
(GP7155A/GP7255A) (36 A-D) 3
36 07630 Plunger Pipe Assy. (36A-D) 3
36A 07667 Plunger Connection 3
36B 07793 Plunger Pipe (50mm) 3
36B 07666 Plunger Pipe (55mm)
(GP7155A/GP7255A) 3
36C 07664 Tension Screw 3
36D 07665 Copper Ring 3
38 13155 Seal Case (GP7155A/GP7255A) 3
5
ITEM PART DESCRIPTION QTY.
38 07794 Seal Case (GP7150A) 3
38A 13156 O-Ring 3
38B 07721 O-Ring (GP7155A/GP7255A) 3
38B 06258 O-Ring (GP7150A) 3
38C 07635 Support Ring (GP7150A Only) 3
39 13157 Seal Sleeve (GP7155A/GP7255A) 3
39 07795 Seal Sleeve (GP7150A) 3
39A 07723 Compact Ring (GP7155A/GP7255A) 3
39A 07796 Compact Ring (GP7150A) 3
40* 07797 Support Disc (GP7155A/GP7255A) 3
41 13158 O-Ring (GP7155A/GP7255A) 3
41 07636 Tension Spring (GP7150A) 3
42 07711 V-Sleeve (GP7155A/GP7255A) 6
42 07638 V-Sleeve (GP7150A) 6
43 07712 Pressure Ring (GP7155A/GP7255A) 3
43 07639 Pressure Ring (GP7150A) 3
44 07637 Support Ring (GP7150A only) 3
49 13159 Stud Bolt 8
49A 13160 Hex Nut 8
50 07790 Valve Casing (GP7155A) 1
50 07791 Valve Casing (GP7255A) 1
50 06628 Valve Casing (GP7150A) 1
50A 13162 Cylinder Stud 2
51 08288 Valve Assembly 6
51A 08281 Spring Tension Cap 6
51B 08282 Valve Spring Guide 6
51C 07732-0100 Valve Spring 6
51D 13164 Valve Plate 6
51E 08283 Valve Seat 6
51F 07653 O-Ring 6
51G 13166 Support Ring 6
51H 07266 O-Ring 6
56 13167 Valve Adaptor 3
56A 07658 O-Ring 6
56B 07635 Support Ring 6
56C 13166 Support Ring 3
56D 07653 O-Ring 3
57 13173 Tension Spring 6
58 13170 Plug 3
59A 07661 Copper Ring 1
60 12251 Plug, 1-1/4” NPT 1
61 12252 Plug, 2-1/2” NPT 1
66 13362 Disc For Crankshaft 1
67 13358 Hexagon Screw 1
* This item may be removed to add a third v-sleeve.
Plunger Packing Kit
# 09526 - GP7150A
Item Part # Description Qty.
38A 13156 O-Ring 3
38B 06258 O-Ring 3
39A 07796 Compact Ring 3
41 07636 O-Ring 3
42 07638 V-Sleeve 6
Plunger Packing Kit
# 9220 - GP7155A & GP7255A
Item Part # Description Qty.
38A 13156 O-Ring 3
38B 07721 O-Ring 3
39A 07223 Compact Ring 3
41 13158 O-Ring 3
42 07711 V-Sleeve 6
Oil Seal Kit - # 09221
Item Part # Description Qty.
32 07624 Radial Shaft Seal 3
32A 07625 Shaft Seal 3
33A 07627 O-Ring 3
Spare Parts List - GP7150A/GP7155A/GP7255A
Valve Kit
# 09606*
Item Part # Description Qty.
51B 08282 Valve Spring Guide 1
51C 07732-0100 Valve Spring 1
51D 13164 Valve Plate 1
51E 08283 Valve Seat 1
51F 07653 O-Ring 2
51G 13166 Support Ring 2
51H 07266 O-Ring 2
56A 07658 O-Ring 2
56B 07635 Support Ring 2
56C 13166 Support Ring 1
56D 07653 O-Ring 1
* Note: When ordering a valve kit for a pump produced
prior to 11/03, order kit #09222, which replaces part
08281 with p/n 13163. Kit 09222 does not require p/n
08282.

6
Specifications
Model GP7150A
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.
HORSEPOWER INFORMATION
Horsepower ratings shown are the power require-
ments for the pump. Gas engine power outputs must
be approximately twice the pump power require-
ments 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
PUMP
PULLEY MOTOR PULLEY RPM GPM 800 PSI 1000 PSI 1300 PSI 1500 PSI 1900 PSI
12.75 5.75 300 23.4 13.4 16.7 21.7 25.1 31.8
12.75 7.50 400 31.2 17.8 22.3 29.0 33.4 42.3
12.75 9.25 500 38.9 22.2 27.8 36.1 41.7 52.8
12.75 11.00 600 46.7 26.7 33.4 43.4 50.0 63.4
12.75 12.75 700 54.5 31.1 38.9 50.6 58.4 74.0
GP7150A PULLEY SELECTION & HORSEPOWER REQUIREMENTS
................................................................U.S. ........................ Metric
Volume.................................................... 54.5 GPM .............. 206 LPM
Discharge Pressure .................................1900 PSI................. 131 Bar
Speed ....................................................................................... 700 RPM
Inlet Pressure .......................................... 140 PSI .................. 10 Bar
Plunger Diameter.................................... 1.97”...................... 50mm
Plunger Stroke ........................................ 1.89”...................... 48mm
Crankshaft Diameter............................... 1.89”...................... 48mm
Key Width............................................... 0.55”...................... 14mm
Crankshaft Mounting............................................................... Either side
Shaft Rotation.......................................................................... Top of pulley towards manifold
Max.Temperature of Pumped Fluids ...... 140 oF .................... 60 oC
Inlet Ports ................................................................................ (2) 2-1/2" NPT
Discharge Ports........................................................................ (2) 1-1/4" NPT
Weight.....................................................374 lbs. ................... 170 kg
Crankcase Oil Capacity ..........................1.6 Gal.................... 6.0 liters
Fluid End Material .................................................................. Bronze
Mechanical Effecency @ 700 RPM ........................................ 0.83
Volumetric Effecency @ 700 RPM ......................................... 0.96

7
TO CHECK VALVES
Lossen plugs (58), take out tension spring (57) and then remove the complete valve (51) with either a valve tool or an
M16 hexagon screw. Remove valve adapter (56) and tension spring (57) with pull-out tool size 5. There is an O-ring
(51G) under both the suction and the discharge valve each of which can be removed with a bent piece of wire.To
disassemble valve hit the top of the valve plate (C) carefully with a bolt and press the valve seat (A) out of the spacer
pipe (E). Check sealing surfaces and replace worn parts. Check O-rings and support rings.Tighten plugs (58) to 107 ft.
lbs.
TO CHECK SEALS AND PLUNGER PIPE
Loosen nuts (49A) and remove pump head. Separate plunger connection (36A) from crosshead (25) by means of two
open-end wrenches (size 22 and 27). Pull seal sleeves (39) out of their fittings in the crankcase.
Take seal case (38) out of seal sleeve (39). Examine plunger parts (36A-36D), seals (42,39A) and O-rings.
When replacing plunger pipe (36B), tighten tension screws (36C) to 30 ft. lbs.
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 spacer pipe (51E) 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
Check O-rings on seal case (38). Clean surfaces of seal sleeves in gear box and sealing surfaces of
valve casing. Push valve casing carefully on O-rings of seal case and centering studs (50A). Tighten nuts (49A) to 103
ft. lbs.
TO DISASSEMBLE GEAR
Take out plunger and seal sleeves as described above. Drain oil. After removing the circleclip 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.
Note: 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 connecing rod and crankshaft (22) take out
bearing cover to one side and push out crankshaft taking particular care that the conrod doesn't gt bent.
Note: Seal (32A) must always be installed so taht the seat up on the inside diameter faces the oil.
Reassemble in revers order: Regulate axial bearing clearance minimum 0.1mm, maximum 0.15-by
GP7150A, GP7155A, GP7255A REPAIR INSTRUCTIONS
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
Water Leaks X
Belts, Pulley X
Plumbing X
Recommended Spare Part
Oil Change (p/n 01154) X
X
Plunger Packing Kits(1 kit/Pump)
See page 5 for kit list
Oil Seal Kit ( 1 kit/Pump
See page 5 for kit list)
Valve Assembly Kit ( 1 kit/pump)
See page 5 for kit list
X
X
X

03/06 GP7150A, GP7155A, GP7255A.PM6
GIANT INDUSTRIES, INC.
900 N. Westwood Ave.
P.O. Box 3187
Toledo, Ohio 43607
[phone]
FAX [phone]
 Copyright 2006 Giant Industries, Inc.
GP7150A, GP7155A, GP7255A SERIES DIMENSIONS - INCHES (mm)
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.
Liabilityunderthiswarrantyisonallnon-wearpartsandlimitedtothereplacementorrepairofthoseproductsreturned
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 [phone]
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 REPRESENTA-
TION,EXPRESSORIMPLIED,INCLUDINGWITHOUTLIMITATIONANYWARRANTIESORMERCHANTABILITY
ORFITNESS FOR APARTICULARPURPOSEAND ALL SUCHWARRANTIESARE HEREBY DISCLAIMED AND
EXCLUDED BY THE MANUFACTURER.