Triplex Ceramic
Plunger Pump
OperatingInstructions/
Repair and Service Manual
Model
GP7128
Contents:
Installation Instructions:
Pump Specifications:
Exploded View:
Parts List/Kits
Repair and Service:
Torque Specs:
page 2
page 3
page 4
page 5
pages 6-8
page 8
Trouble Shooting Chart: page 9
Recommended Spare
Parts List:
Dimensions:
page 10
page 11
WarrantyInformation:
back page
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Specifications
Model GP7128
Flow ..................................................................... 17.9 GPM ..................... 67.7 Liters/minute
1
Discharge Pressure ............................................. 5800 PSI1
......................................
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 ................................................................................ Top of pulley towards manifold
o
Temperature of Pumped Fluids............................ 140 oF ........................... 60 C
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
400 9.5
550 13.1
600 14.3
650 15.5
700 16.7
750 17.9
15.4
20.4
28.1
30.6
33.2
35.8
38.4
20.6
27.1
37.4
40.9
44.3
47.7
51.1
25.7
33.9
46.8
51.1
55.4
59.6
63.9
29.8
39.4
54.3
59.2
64.2
69.2
74.2
HORSEPOWER RATINGS:
We recommend a 1.1 service factor be specified
when selecting an electric motor as the power
The rating shown are the power requirements for the source.
pump. Gas engine power outputs must be
approximately twice the pump power requirements
shown above.
To compute specific pump horsepower requirements,
use the following formula:
GPM X PSI
1400
= hp
3
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Exploded View - GP7128 Pump
4
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GP7128 PARTS LIST
ITEM
1
2
4
5
8
9
10
11
12
13
14
15
16
20
20A
21
22
PART
07600
13000
07601
07602
07603
01009
22706
06725
07109
07182
07607
07608
07184
07610
07611
07612
13405
07614
13182
07616
08041
13183
13184
07619
DESCRIPTION
Crankcase
OilFillerPlugAssembly
CrankcaseCover
Seal for Cover
OilDipStick
O-Ring,DipStick
InnerHexagonScrew
Spring Washer
DrainPlug
Gasket,DrainPlug
BearingCover
RadialShaftSeal
O-Ring,Bearingcover
TaperRollerBearing
FittingDisc(Shim)
Shaft Protector
Crankshaft
QTY.
1
1
1
1
1
1
12
12
2
2
2
2
2
2
1-5
1
1
1
3
6
6
3
3
1
8
4
8
1
1
3
3
3
3
3
ITEM
38A
38B
38C
38D
39
39A
41
42
43
43A
45
49
49A
50
PART
12055
07693
07354
12056
06426
13228
13417
13369
06862
05355
07173
13159
13160
06099
13162
13146
12056
07354
13131
13130
07062
13147
13148
06078
13149
07699
07700
07693
07702
07703
07704
13150
13151
13362
13358
07662
17212
DESCRIPTION
O-Ring,SealCase
Support Ring for 38A
O-Ringfor39
Support Ring for 38C
SealSleeve
GroovedRing
Pressure Ring
V-Sleeve
Sleeve Support Ring
SpacerRing
Tension Spring
Stud Bolt
HexagonNut
ValveCasing
CylinderStud
Inlet Valve Assy.
Support Ring
O-Ring
InletValveSeat
ValvePlate
ValveSpring
SpacerPipe
Discharge Valve Assy.
Compression Spring
Discharge Valve Seat
Plug
O-Ring
Support Ring
HexagonScrew
Plug,3/4"
CopperRingfor59
Plug,3/4”BSP
Plug,1-1/4”BSP
Disc for Crankshaft
HexagonScrew
Tool for valve assembly
Crankcase Assembly
(1-34/49/49A/50A/66/67)
QTY.
3
3
3
3
3
3
3
3
3
3
3
8
8
1
2
3
6
6
3
6
6
6
3
3
3
3
3
3
12
3
3
1
50A
51
51A
51B
51C
51D
51E
51F
52
57
52C
58
58A
58B
58C
59
59A
60
23
24
24A
24B
25
Key
Connecting Rod Assy.
FittingScrew
Washer
Crosshead Assy.
Crosshead Pin
CoverPlate
28
30
30A
30B
30C
30D
31
32
32A
33
33A
33B
33C
34
36
38
07225-0100 HexagonScrew
13136
08280
13154
07623
07624
07625
07626
07627
07628
07249
13137
06427
05354
Grommet
Disc
Cover
EyeBolt
RadialShaftSeal
CompactRing
SealRetainer
O-Ringfor33
Circlipfor33
Shim
61
66
67
1
1
1
3
3
3
3
Flinger
Plunger
Seal Case
GP7128 Pump Repair Kits
Plunger Packing Kit - 09464
Item Part # Description
38A 12055 O-Ring, Seal Case
38B 07693 Support Ring
38C 07354 O-Ring
Valve Assembly Kit - #09520
Item Part # Description
51A 12056 Support Ring
51B 07354 O-Ring
51C 13131 InletValveSeat
51D 13130 ValvePlate
51E 07062 ValveSpring
Qty.
3
3
3
3
Qty.
6
6
3
6
38D 12056 Support Ring
39A 13228 Grooved Ring
3
6
42
43
13369 V-Sleeve
06862 Sleeve Support Ring
6
3
52C 13149 Discharge Valve Seat 3
58A 07700 O-Ring
3
6
58B 07693 Support Ring
Oil Seal Kit # 09225
Item Part # Description
Qty.
3
32
07624 Radial Shaft Seal
32A 07625 Ring
3
33A 07627 O-Ring
3
5
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GP7128 Repair Instructions
NOTE: Alwaystaketimetolubricateallmetalandnon-metalpartswithalightfilmofoil
beforereassembling. Thisstepwillhelpensureproperfit,atthesametimeprotecting
thepumpnon-metalparts(elastomers)fromcuttingandscoring.
1. Lossen screws (58C), take
plugs (58) out of valve cas-
ing with two screws.
2. Take out complete valve
assemblies (51 and 52) us-
ing either tool (part
#07662) or stud bolt.
3. Valve seats (51C and 52C)
are pressed out of spacer
pipe (51F) by hitting the
valve plate (51D) with a
bolt.
S
P
51F
51E
51C
51B
51A
51C or 52C
or 52C
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 al-
ways 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).
4. Check surfaces of valve plate, valve seat, O-rings (51B, 58A) and
replace worn parts.
6. Loosen nuts (49A)
7. Remove pump head.
6
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GP7128 Repair Instructions
8. Separate plunger (36) from
crosshead (25) by means of
one open-end wrench.
9. Pull seal sleeves (39) out of
their fittings in the crank-
case. Take seal case (38)
out of seal sleeve (39).
38D
38C
38
38B
38A
36
10. If o-rings (38A and 38C) or support rings (38B and 38D) are
damaged, replace with new parts. Examine plunger (36) for wear.
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).
7
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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
0.15mm-by means of fitting disc (20A). The crankshaft (22) should turn
clearance. Tighten fitting screws (24A) to 30 ft.-lbs. (40 NM)
0.1mm, maximum
easily with little
CAUTION: Connecting rod (24) has to be able to be slightly moved sidewise at the stroke journals.
GP7128 Torque Specifications
Position
24A
36
Item#
07616
07664
13160
07699
Description
Fitting Screw
Tensioning Screw
Nut
Torque Amount
30 ft-lbs. (40NM)
33 ft.-lbs. (45NM)
103 ft.-lbs.(140NM)
156 ft.-lbs.(210NM)
49A
58
Plug
8
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PUMP SYSTEM MALFUNCTIONS
MALFUNCTION
CAUSE
REMEDY
The Pressure and/
Worn packing seals
Replace packing seals
or the Delivery Drops
Broken valve springs
Belt slippage
Worn or Damaged nozzle
Fouled discharge valve
Replace springs
Tighten or Replace belt
Replace nozzle
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
Water in Crankcase
Noisy Operating
High Humidity
Worn Seals
Reduce oil change intervals
Replace seals
Worn bearings
Cavitation
Replace bearings, Refill
crankcase oil with recommended
lubricant
Check inlet lines for restrictions
and/or proper sizing
Rough/Pulsating
Operation with
Pressure Drop
Worn packing
Inlet restriction
Accumulator pressure
Replace packing
Check system for stoppage
air leaks, correctly sized
inlet plumbing to pump
Recharge/Replace accumulator
Unloader
Cavitation
Check for proper operation
Check inlet lines for restrictions
and/or proper size
Pump Pressure as
Drop at gun Rated,
Pressure
Restricted discharge plumbing
Re-size discharge plumbing to flow
rate of pump
Excessive
Leakage
Worn plungers
Replace plungers
Worn packing/seals
Adjust or Replace packing seals
Excessive vacuum
Cracked plungers
Reduce suction vacuum
Replace plungers
Inlet pressure too high
Reduce inlet pressure
High Crankcase
Temperature
Wrong Grade of Oil
Giant oil is recommended
Improper amount of oil in crankcase
Adjust oil level to proper amount
9
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Preventative Maintenance Check-List & Recommended Spare Parts List
Check
Daily
Weekly
50hrs
Every
500 hrs
Every
1500 hrs
Every
3000 hrs
Oil Level/Quality
Oil Leaks
Water Leaks
Belts, Pulley
Plumbing
X
X
X
X
X
Recommended Spare Parts
Oil Change (1 Gallon) p/n 1154
Plunger Packing Kits (1kit/pump)
(See page 5 for kit list)
ValveAssembly Kit (1 kit/pump)
(See page 5 for kit list)
X
X
X
X
X
Oil Seal Kit (1 kit/pump)
(See page 5 for kit list)
10
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GP7128 Dimensions - Inches (mm)
11
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GIANTINDUSTRIESLIMITEDWARRANTY
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,EXPRESSORIMPLIED,INCLUDINGWITHOUTLIMITATIONANYWARRAN-
TIES 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
Copyright 2007 Giant Industries, Inc.
GP7128.PMD
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