Giant GP7170-4000 User manual

Contents:
Installation Instructions: page 2
Pump Specifications: page 3
Exploded View: page 4
PartsList/Kits: page 5
Repair Instructions: pages 6-7
Torque Specifications: page 7
Recommended
Spare Parts List: page 7
WarrantyInformation: back page
Triplex Ceramic
Plunger Pump
OperatingInstructions/
Repair and Service
Manual
Model
GP7170-4000

2
INSTALLATIONINSTRUCTIONS
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 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
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.
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
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. Use Giant
recommended oil. 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.
°
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 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 ob-
tained 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.
* Important - Check torque bi-weekly on item 49A

3
U.S. .............................. Metric
Volume .................................................................84.5 GPM ..................... 320 LPM
Discharge Pressure .............................................1450 PSI....................... 100 bar
Speed .......................................................................................................... Up to 700 RPM
Inlet Pressure.............................................................................................. Up to 90 PSI2 (10 bar)
Plunger Diameter................................................. 2.48”............................. 63 mm
Plunger Stroke .....................................................2.05” ............................. 52mm
Crankshaft Diameter ...........................................2.05”............................. 52mm
Key Width ................................................................................................... 14mm
Crankshaft Mounting .................................................................................. Either side
Shaft Rotation ................................................................................ Top of pulley towards manifold
Temperature of Pumped Fluids............................140 oF ........................... 60oC
Inlet Ports ................................................................................................... (2) 1 1/4" NPT
Discharge Ports .......................................................................................... (2) 3/4" NPT
Weight ..................................................................374 lbs. ......................... 170 kg
Crankcase Oil Capacity .......................................1.6 Gal. ......................... 6.0 liters
FluidEnd Material....................................................................................... Stainless Steel
Specifications
Model GP7170-4000
HORSEPOWER RATINGS:
The rating shown are the power require-
ments 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 followingformula: GPM X PSI
1400
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.
= hp
PUMP
PULLEY MOTOR PULLEY RPM GPM 500 PSI 750 PSI 1000 PSI 1500 PSI
12.75 7.00 300 36.0 12.9 19.3 25.7 38.6
12.75 9.20 400 49.0 17.5 26.3 35.0 52.5
12.75 11.45 500 60.0 21.4 32.1 42.9 64.3
12.75 12.75 700 84.5 30.2 45.3 60.4 90.5
GP7170 PULLEY SELECTION & HORSEPOWER
REQUIREMENTS

Exploded View - GP7170-4000
4

GP7170-4000 PARTS LIST
ITEM PART DESCRIPTION QTY.
1 06653 Crankcase 1
2 13000 OilFillerPlugAssembly 1
4 07601 CrankcaseCover 1
5 07602 SealforCrankcaseCover 1
8 07603 OilDipStick 1
9 01009 O-Ring,DipStick 1
10 22706 HexagonScrew 12
11 06725 Spring Washer 12
12 07109-0400 DrainPlug 5
13 07182 Gasket,DrainPlug 2
14 07607 BearingCover 2
15 07608 RadialShaftSeal 2
16 07184 O-RingforBearingCover 2
20 07610 TaperRollerBearing 2
20A 07611 FittingDisc(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 06661 CoverPlate 1
30A
07225-0100 HexagonScrew 4
30B 13136 Grommet 4
30C 08280 Disc 4
31 07623 EyeBolt 1
32 07624 RadialShaftSeal 3
33 06662 SealRetainer 3
33A 13286 O-RingforSealRetainer 3
33B 05229 CirclipforSealRetainer 3
33C 05230 FittingDisc 3
34 13137 OilScraper(Flinger) 3
36 05231 Plunger Pipe Assembly (36A-36D) 3
36A 07667 Plunger Base 3
36B 05232 PlungerPipe 3
36C 07664 Tensioning Screw 3
36D 07665 CopperRing 3
37 05233 IntermediateCasing 1
ITEM PART DESCRIPTION QTY.
38 05234 SealSleeve 3
39 05235 O-RingforSealRetainer 3
40 05236 Pressure Ring 3
41 05237 DripReturnRing 3
42 05238 O-Ring 3
43 05239 Pressure Ring 3
44 05240 Sleeve 9
45 05241 Sleeve Support Ring 3
46 05071 Seal Tension Spring 3
47 05242 SealCase 3
47A 06667 O-Ring 6
48 05243 Discharge Casing 1
49 06675 Stud Bolt 8
49A 06958 HexagonNut 8
50 05244 ValveCasing 1
50A 13162 CylinderStud 4
51 05245 ValveAssembly 6
51A 05246 ValveSeat 6
51B 07653 O-RingforValveSeat 6
51C 05247 ValvePlate 6
51D 07732-0100 ValveSpring 6
51E 08281 SpacerPipe 6
51F 05248 ValveSpringGuide 6
52 05249 Pressure Valve Adapter 3
52A 07658 O-Ring 6
53 13173 Tension Spring 6
54 05250 InnerHexagonScrew 8
55 05251 DripReturnConnection 1
55A 22764 SerratedPin 1
56 05252 DripReturnPlug 1
57 05253 O-Ring 2
58 05254 LeakageSeal 2
59A 06807 SteelRing(Gasket) 1
60 13151 Plug1-1/4”BSP 1
61 12252-5000 Plug2-1/2”BSP 1
66 13362 Discfor Crankshaft 1
67 13358 HexagonScrew 1
07662 SlideHammerTool(notshown) 1
5
I
GP7170-4000 REPAIR KITS
Plunger Packing Kit # 09610
Item Part # Description Qty.
39 05235 O-RingforSeal Retainer 3
42 05238 O-Ring 3
44 05240 V-Sleeve 9
47A 05242 O-Ring 6
Oil Seal Kit # 09612
Item Part # Description Qty.
32 07624 RadialShaftSeal 3
33A 07627 O-Ring 3
InletValveAssemblyKit #09611
Item Part # Description Qty.
51A 05246 Valve Seat 1
51B 07653 O-RingforValveSeat 1
51C 05247 InletValve Seat 1
51D 07732-0100 Valve Spring 1
51F 05248 Valve Spring Guide 1
52A 07658 O-Ring 2

6
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.
ToCheckValves
1) Loosen and remove screws (54 with a 10mm allen wrench.
2) Remove discharge casing (48) and valve tension springs (53).
3) Remove the discharge valves (51) by screwing supplied valve-puller into the top of the spacer pipe (51E) and firmly
sliding upward with the puller handle. NOTE: The pressure valve adapter (52) will typically come out attached to the
discharge valve. To remove, firmly grasp both pieces and rock them back and forth to break the O-ring seal on the O.D.
of the valve seat.
4) Remove the inlet valves using the same procedure as above.
5) Unscrew the valve seat (51A) from the spacer pipe (51E). Remove the valve spring (51D) and valve spring guide (51F)
and inspect for wear. Replace parts as necessary
6) Check surfaces of valve plate (51C), valve seat (51A), O-rings (51B) and replace worn parts.
7) To reinstall the inlet valves (51), screw the valve puller back into the top of the valve assembly (51). Lower the valve
into the chamber and press firmly into the bottom of the chamber to ensure the valve is seated properly. Install the
tension spring (53).
8) To reinstall the discharge valves, press the discharge valve (51) into the pressure valve adapter (52). Push the entire
assembly into the chamber. Reinstall the tension spring (53).
9) Reinstall the discharge casing (48) and tighten bolts (54) to 155 ft-lbs. in a criss-cross pattern starting with the
centermost 4 bolts and working outward.
ToChange Seals
10) Loosen nuts (49A) with a 24mm socket wrench.
11) With a rubber mallet tap the back of the valve casing (50) and pull the valve casing off the stud bolt (49).
12) Remove cover plate (30) with a 10mm socket wrench.
13) By gripping hex flats, separate plunger assembly (36) from crosshead (25) by means of two open-end wrenches (size
22mmand27mm).
CAUTION: Do not loosen the 3 plunger bases (36A) before the valve casing has been removed otherwise the
plunger assembly (36) could hit against the spacer pipe (52) when the pump is being turned.
14) Remove the intermediate casing (37) from the crankcase (1).
15) Use two screwdrivers to pry the seal case (47) out of the intermediate casing (37). Remove pressure ring (43), V sleeves
(44), sleeve support ring (45), seal tension spring (46), and O rings (47A). Inspect parts for wear and replace as neces-
sary.
16) Remove the seal sleeve (38), O ring (39), pressure ring (40), V sleeve (44), O ring (42) and drip return ring (41) from the
crankcase (1). Inspect parts for wear and replace as necessary.
17) Inspect the plunger pipe for cavitation, cracks, or any other signs of wear. If replacing plunger pipe, tighten plunger bolt
(36C)to 26ft-lbs.
18) Reassemble all parts in reverse order taking care to lubricate all seals and O rings with silicone grease prior to installa-
tion. Reinstall plunger pipe assemblies (36) into intermediate casing (37). When installing the intermediate casing (37)
and valve casing (50) be sure that the parts rest on the studs (50A) and that they have not fallen out.
19) Reinstall valve casing (50) and tighten nuts (49A) to 103 ft-lbs.
ToChange Oil Seals
20) Remove C-clip (33B) from crankcase (1) and remove seal retainer (33).
21) Remove O ring (33A) and radial shaft seal (32) and replace as necessary.
22) Reinstall seal retainer (33) and secure with C-clip (33B) in crankcase.
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.
ToDisassembleGearEnd
23) Remove entire manifold and intermediate casing assembly using procedures described above. Take out plunger
assembly (36). Drain oil.
GP7170-4000 REPAIR INSTRUCTIONS

7
GP7170-4000 REPAIR INSTRUCTIONS
PreventativeMaintenance Check-List &Recommended SpareParts List
Check Daily Weekly 50hrs Every Every Every
500 hrs 1500 hrs 3000 hrs
OilLevel/Quality X
OilLeaks X
Water Leaks X
Belts,Pulley X
Plumbing X
RecommendedSpareParts
OilChange X X
Plunger Spare Parts (1 kit/pump) X
(See page 5 for kit list)
Oil Seal Kit (1 kit/pump) X
(See page 5 for kit lit)
Valve Spare Parts (1 kit/pump) X
(See page 5 for kit list)
24) After removing the C-clip (33B), pry out seal adapter (33) with a screwdriver.
25) Check seals (32) and surfaces of plunger base (25).
26) 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.
27) Check surfaces of the connecting rod (24) and crankshaft (22).
28) Take out bearing cover (14) to one side and push out crankshaft (22) taking particular care that the connecting rod (24)
doesn’t bend.
29) Reassemble inreverse order: Regulate axial bearingclearance - minimum 0.1mm, maximum0.15mm-by meansof 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.
30) Reassemble cover (4) and seal (5) onto crankcase (1). Fasten with hexagon screws (10).
31) Reinstall shim (33C), and seal adapter (33) with radial shaft seal (32), and o-ring (33A) onto crankcase (1).
CAUTION: Radial shaft seal (32) must always be installed so that the seal-lip on the inside diameter faces the oil.
32) Reinstall remainder of fluid end as described above.
GP7170-4000 TORQUE SPECIFICATIONS
Position Item# Description TorqueAmount(ft.-lbs.)
36C 07664 PlungerTensioning Screw 26
49A* 13160 Nut 103
54 05250 InnerHexagon Screw 155
*Important - Check torque bi-weekly on item 49A

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
warrantedfor five yearsfrom the dateof shipment forall pumps usedin 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.
Thiswarrantyislimitedtorepairorreplacementofpumpsandaccessoriesofwhichthe 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
workmanshiporfailureofmaterial. AReturnedGoodsAuthorization(R.G.A.)numberandcompleted
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
hereunderandthe MANUFACTURERSHALLNOTBE LIABLEFORFURTHERLOSS, 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-
RANTIESORMERCHANTABILITYORFITNESSFORAPARTICULARPURPOSEANDALLSUCH
WARRANTIES ARE HEREBY DISCLAIMED AND EXCLUDED BY THE MANUFACTURER.
07/06 GP7170-4000.PM6
GIANT INDUSTRIES, INC., 900 N. Westwood Ave., P.O. Box 3187, Toledo, Ohio 43607
PHONE [phone], FAX [phone], www.giantpumps.com
 Copyright 2006 Giant Industries, Inc.