Model

BP7170

Triplex Ceramic

Plunger Pump

Operating Instructions/

Repair and Service Manual

Contents:

Installation Instructions:

BP7170 Pump

Specifications:

Exploded View:

Parts List:

Recommended Spare

Parts List / Kit List:

Repair Instructions:

Pump mounting selection

Guide:

Pump System Malfunction:

Dimensions:

Warranty Information page 2 page 3 page 4 page 5 page 6 pages 7-9 page 9 page 10 page 11 back page

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.

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.

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 o

F, it is important to insure a positive head to the pump to prevent cavitation.

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 charts on page 3.

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 shutoff 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

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 oil level is between the two lines on the oil dipstick. DO NOT OVERFILL. Use recom-

mended Giant 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.

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.

NOTE: Contact Giant Industries for Service School Information. Phone: (419)-531-4600.

2

Specifications

Model BP7170

Volume ................................................................................................... Up to 84.5 GPM (320 lm)

Discharge Pressure ................................................................................. Up to 1015 PSI (70bar)

Speed ..................................................................................................... Up to 560 RPM

Inlet Pressure .......................................................................................... Up to 140 PSI (10 bar)

Plunger Diameter .................................................................................... 70mm

Plunger Stroke ........................................................................................ 52mm

Crankshaft Diameter ............................................................................... 48mm

Key Width .............................................................................................. 14mm

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

Shaft Rotation ............................................................................ Top of pulley towards manifold

Temperature of Pumped Fluids ............................................................... Up to 140 o

F (60 o

C)

Inlet Ports ............................................................................................... (2) 2-1/2" NPT

Discharge Ports ...................................................................................... (2) 1-1/4" NPT

Weight .................................................................................................... 423 lbs. (191 kg)

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

Fluid End Material ................................................................................. Cast Iron

Mechanical Effecency @ 700 RPM ........................................................ 0.83

Volumetric Effecency @ 700 RPM ......................................................... 0.95

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 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:

GPM X PSI

=hp

1400

BP7170 PULLEY SELECTION & HORSEPOWER

REQUIREMENTS

PUMP

PULLEY

12.75

12.75

12.75

12.75

MOTOR

PULLEY

7.00

9.20

11.45

12.75

RPM GPM 500 PSI 700 PSI 900 PSI 1015 PSI

300 45.3

400 60.4

500 75.4

560 84.5

16.2

21.6

26.9

30.2

22.7

30.2

37.7

42.3

29.1

38.8

48.5

54.3

32.8

43.8

54.7

61.3

SPECIAL NOTE:

The theoretical gallons per revolution (gal/rev) is 0.151.

To find specific outputs at various RPM, use the formula:

GPM = 0.151 x RPM

3

Exploded View - BP7170

*

4

PARTS LIST - BP7170

11

12

13

8

9

10

2

4

5

ITEM PART

1 06653

06654

06655

07601

07602

07603

06225

13133

07109

07182

25

28

30

22

23

24

14

15

16

07608

07184

20 07610

20A 07611

21 07612

13405

07614

13182

13183

13184

07619

DESCRIPTION

Crankcase

Oil Filler Plug Assembly

Crankcase Cover

Gasket, Crankcase Cover

Oil Dip Stick

O-Ring, Dip Stick

Hexagon Screw

Spring Washer

Drain Plug

Gasket, Drain Plug

Bearing Cover

Radial Shaft Seal

O-Ring

Taper Roller Bearing

Fitting Disc (Shim)

Shaft Protector

Crankshaft

Key

Connecting Rod Assy.

Crosshead Assy.

Crosshead Pin

Cover Plate

30A 07225-0100 Hexagon Screw

30B 13136 Grommet

30C 07622 Washer

30D 13154

31 07623

32 07624

Cover Plate

Eye Bolt

Radial Shaft Seal

32A 07625

33 07626

33A 07627

33B 07628

34 13137

36 07706

Shaft Seal

Seal Retainer

O-Ring

Circlip

Oil Scraper

Plunger Pipe Assy.

36

36A

36B

36B

38

07630

07667

07666

07793

36C 07664

36D 07665

38 13155

07794

(GP7155A/GP7255A) (36 A-D) 3

Plunger Pipe Assy. (36A-D) 3

Plunger Connection 3

Plunger Pipe

(GP7155A/GP7255A)

Plunger Pipe

3

3

Tension Screw

Copper Ring

Seal Case (GP7155A/GP7255A) 3

3

3

Seal Case 3

3

3

3

3

3

1

1

3

8

4

8

3

3

1

1

1

3

2

1-5

1

2

2

2

12

3

2

1

1

12

QTY.

1

1

1

1

51 13174

51A 13163

51B 07653

51C 13164

51D 07732

51E 13165

51F 13166

51G 07266

56 13167

56 07744

56A 07658

56B 07635

56C 13168

56D 07653

57 13173

58 13170

59A 07661

66 13362

67 13358

ITEM PART

38A 13156

38B 07721

38B 06258

38C 07635

39

39

13157

07795

39A 07723

39A 07796

40* 07797

41 13158

43

43

44

41

42

42

07636

07711

07638

07712

07639

07637

49 13159

49A 13160

50 07790

50

50

07791

06628

50A 13162

* This item may be removed to add a third v-sleeve.

DESCRIPTION

O-Ring

O-Ring (GP7155A/GP7255A)

O-Ring (GP7150A)

Support Ring (GP7150A Only)

Seal Sleeve (GP7155A/GP7255A) 3

Seal Sleeve (GP7150A) 3

Compact Ring (GP7155A/GP7255A)3

Compact Ring (GP7150A)

Support Disc (GP7150A)

O-Ring (GP7155A/GP7255A)

3

3

3

QTY.

3

3

3

3

O-Ring 3

V-Sleeve (GP7155A/GP7255A) 6

V-Sleeve 6

Pressure Ring (GP7155A/GP7255A)3

Pressure Ring 3

Stud Bolt 3

Stud Bolt

Hex Nut

Valve Casing (GP7155A)

Valve Casing (GP7255A)

Valve Casing (GP7150A)

Cylinder Stud

1

1

2

8

8

1

Valve Assembly

Valve Seat

O-Ring

Valve Plate

Valve Spring

Spacer Pipe

Support Ring

O-Ring (GP7155A ONLY)

Valve Adaptor (GP7155A/GP7255A) 3

6

6

Valve Adaptor (GP7150A)

O-Ring

Support Ring

3

6

6

6

6

6

6

6

6

Support Ring

O-Ring

Tension Spring

Plug M64 X 2

Copper Ring

Disc For Crankshaft

Hexagon Screw

3

1

1

3

3

6

1

5

Plunger Packing Kit

# 09558

Item Part # Description

38A

41

06667 O-Ring

06670 Spiral Ring

42 06671 Support Ring

38A 06667 O-Ring

Qty.

6

6

6

3

Oil Seal Kit

# 09557

Item Part # Description

32

32A

Qty.

07624 Radial Shaft Seal 3

07625 Compact-Ring 3

33A 13286 O-Ring 3

REPAIR KITS - BP7170

Valve Repair Kit

# 09559

Item Part # Description

51A

51B

06677 Valve Seat

07653 O-Ring

51C

51D

51E

51F

56A

56B

06678 Valve Plate

07732 Valve Spring

06679 Spacer Pipe

06680 Ring for Valve

07658 O-Ring

07635 Support Ring

6

6

6

6

3

3

Qty.

3

6

Check

Preventative Maintenance Check-List & Recommended Spare Parts List

Daily Weekly 50hrs Every Every

500 hrs 1500 hrs

Every

3000 hrs

Oil Level/Quality

Oil Leaks

Water Leaks

Belts, Pulley

Plumbing

X

X

X

X

X

Recommended Spare Parts

X X Oil Change p/n 1154

Seal Spare Parts (1 kit/pump)

(See page 6 for kit list)

Oil Seal Kit (1 kit/pump)

(See page 6 for kit lit)

Valve Spare Parts (1 kit/pump)

(See page 6 for kit list)

X

X

X

Important: Seal unit (40, 41, 42

see page 7) can only be installed after the intermediate casing (48) with guide rings (43) has been mounted to the drive. The seal unit is then mounted on to the plunger pipe and push.it into the intermediate casing using a sleeve or tension spring.

Important: The seal unit (40, 41, 42

see page 7) is tensioned by a spring

(39). To achieve long seal life, the unit is tensioned in such a way that a small amount of leakage can occur.

This helps to lubricate and cool the seal. A seal change is only then necessary when leakage increases considerably, in turn causing flow and pressure to fall.

6

BP7170 REPAIR INSTRUCTIONS

NOTE: Always take time to lubricate all metal and nonmetal parts with a light film of oil before reassembly.

This step will ensure proper fit, at the same time protecting the pump nonmetal parts (i.e., the elastomers) from cutting and scoring.

1.

Remove plugs (58) and remove pressure springs

(57).

51E 51D 51C 51F 52A

2.

Using either a pin spanner or pliers, take out complete discharge valve (52), tension spring (57) and suction valve (51).

Dismantling valves: the spring tension cap (51 E) is screwed together with valve seat (51A or 52A). Remove spring tension cap, remove spring (51 D) and valve plate (51 C). The seal ring (51 F) is snapped on to the valve plate. Check sealing surfaces, o-rings (51B/56A) and support rings (56B). Replace worn parts.

3.

Remove inner hexagon screws (49A)

4.

Remove pumphead together with seal case (38) from intermediate casing (48).

5.

Take tension springs (39), out of intermediate casing

(48).

42 41 40

6.

Using two screwdrivers, pry off intermediate casing (48) from valve casing and remove by moving it past the plunger pipes.

7.

Remove seal unit (40, 41, 42) by pressing it outwards past the plunger pipe. Examine spiral rings (41) and support rings (42).

7

43 44 42

8.

Pull guide ring (43) out of crankcase (1). Examine o-ring

(44) and (42).

38A 38 38A

10.

Remove seal cases (38) from valve casing (50) and check orings (38A). Replace worn parts. Apply silicon grease on seals and o-rings before installing again.

Important: Mounting surfaces of the crankcase and interme-

diate casing must be clean and free of damage. The components must line up exactly and evenly on one another. The same exactness applies for all centering positions within the crankcase, intermediate and valve casing.

36C 36D 36B 36A

11.

If the plunger pipe (36B) is worn, tap the tension screw (36C) lightly with a plastic hammer beforehand to loosen the glue on the threads of the tension screw.Then remove tension screw

(36C) and remove the plunger pipe from plunger connection

(36A). Using the tension screw, put the new plunger pipe with a new copper ring (36D) on to the plunger connection. Cover the threads of the tension screw lightly with Locktight 243 and tighten at 30 ft-lbs.

8

Important: Care must be

taken that locktight does not get between the plunger pipe

(36B) and the plunger connection (36A).

Overtensioning of the plunger pipe by eccentric tightening of the tension screw and/or dirt or damage on the mounting surfaces can lead to plunger pipe breakage.

12.

Check mounting and sealing surfaces of the crankcase

(1), intermediate casing (48) and valve casing (50), and clean where neassary.

Put seal cases (38) in the centring holes of the valve casing, then push valve casing carefully onto centring studs (50A).

Tighten hexagon nuts (49) at 103 ft-lbs.

13.

Take out plunger pipe and seal sleeves as described above. Drain oil. After removing the circlip ring

(33B) pry out seal retainer

(33) with a screwdriver.

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

Remove crankcase cover

(4). Loosen fitting screws on the connecting rods (24) and connecting rod halves as far into the crosshead guide as possible.

Important: Connecting rods

are marked for identification. Do not twist connecting rod halves. Connecting rods are to be reinstalled in their exact original position on the shaft journals. Check surfaces of connecting rod

(24) and crankshaft (22)

Take out one bearing cover on one side and push out crankshaft making sure not to bend the connecting rods.

Important: 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 0.1 mm, maximum 0.1 5mm by means of fitting discs (20A).

Shaft should turn easily with little clearance. Tighten fitting screws (24) at 30 ftlbs.

Important: Connecting

rods must be able to move slightly sideways at the stroke journals

Pump Mounting Selection Guide

Bushings

01074 - 24 mm Tapered H Bushing

Pulley & Sheaves

01061 - 7.75” Cast Iron 1 gr. - AB Section

01062 - 7.75” Cast Iron - 2 gr. - AB Section

Rails

01160 - Plated Steel Channel Rails

(L=5.75”x W=1.00”x h=2.50”)

01161 - Plated Steel Channel Rails

(L=5.75”x W=1.00”x H=2.50”)

9

MALFUNCTION

The Pressure and/ or the Delivery

Drops

Water in crankcase

Noisy Operation

Rough/Pulsating

Operation with

Pressure Drop

Pump Pressure as

Rated, Pressure

Drop at gun

Excessive

Leakage

High Crankcase

Temperature

PUMP SYSTEM MALFUNCTION

CAUSE REMEDY

Worn packing seals

Broken valve spring

Belt slippage

Worn or Damaged nozzle

Fouled discharge valve

Fouled inlet strainer

Worn or Damaged hose

Worn or Plugged relief valve on pump

Cavitation pump for restrictions

Unloader

High humidity

Worn seals

Worn bearings oil with

Cavitation

Worn packing

Inlet restriction

Accumulator pressure

Unloader

Cavitation

Restricted discharge plumbing

Replace packing seals

Replace spring

Tighten or Replace belt

Replace nozzle

Clean valve assembly

Clean strainer

Repair/Replace hose

Clean, Reset, and Replace worn parts

Check suction lines on inlet of

Check for proper operation

Reduce oil change interval

Replace seals

Replace bearings, Refill crankcase

recommended lubricant

Check inlet lines for restrictions and/or proper sizing

Replace packing

Check system for stoppage, air leaks, correctly sized inlet plumbing to pump

Recharge/Replace accumulator

Check for proper operation

Check inlet lines for restrictions and/or proper size

Re-size discharge plumbing to flow rate of pump

Worn plungers

Worn packing/seals

Excessive vacuum

Cracked plungers

Inlet pressure too high

Wrong Grade of oil

Improper amount of oil in crankcase

Replace plungers

Adjust or Replace packing seals

Reduce suction vacuum

Replace plungers

Reduce inlet pressure

Giant oil is recommended

Adjust oil level to proper amount

10

BP7170 DIMENSIONS - INCHES (mm)

11

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 REPRESENTA-

TION, 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

(419) 531-4600

FAX (419) 531-6836



Copyright 2002 Giant Industries, Inc.

10/02 BP7170A.PM6