Giant GP6124 User's Manual
Contents
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 warranted for five years from the date of 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 Normal wear and tear to standard wear parts Use of repair parts other than those manufactured or authorized by Giant Improper use of the product as a component part Changes or modifications made by the customer or third party 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 to2. 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 FURTHERLOSS 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 ORIMPLIED INCLUDING WITHOUT LIMITATION ANY WARRAN TI ABILITY OR FITNESS FOR A PARTICULAR PURPOSE AND ALL SUCH Ga GIANT INDUSTRIES INC 900 N Westwood Ave P O Box 3187 Toledo Ohio 43607 PHONE 419 531 4600 FAX 419 531 6836 www giantoumps com Copyright 1997 Giant Industries Inc 3 98GP6124_8 PM6
3. Hexagon Screw GP6124 amp GP6128 REPAIR KITS 09311 Description Qty 3 07721 07693 12055 07685 13400 13238 07718 Part Valve Assembly Kits GP6124 09312 Description O Ring 6 Support Ring 6 O Ring 6 Packing 12 Grooved Ring 3 Leakage Seal Support Ring Qty GP6128 07064 13130 07062 07150 06266 Part Valve Seat Valve Plate Valve Spring O Ring Support Ring 09303 Description 09302 6 Description 6 O Ring 6 Support Ring 12 O Ring 3 Support Ring V Sleeve Leakage Seal 07064 07063 07062 07150 06266 Valve Seat Valve Plate Valve Spring O Ring Support Ring Oil Seal Kit 09304 Qty 3 3 3 Partt Description 06118 13215 07721 Grooved Ring O Ring Radial Shaft Seal Specifications Model GP6128 Volume Up to 18 0 GPM Discharge Pressure Up to 4000 PSI Up to 800 RPM Inlet Pressure Up to 90 PSI Plunger Diameter Plunger Stroke Crankshaft Diameter Key Width Crankshaft Mounting Either side Shaft Rotation Top of pulley towards manifold Temperature of Pumped Fluids Up to 140 F Inlet Ports 2 1 1 2 NPT Discharge Ports 2 1 NPT Crankcase Oil Capacity Fluid End Material 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 Positive inlet pressures are recommended HORSEPOWER RATINGS The rating shown are the power requirem
4. Triplex Ceramic Plunger Pump M odel Operating Instructions GP6124 amp GP6128 Contents Installation Instructions page 2 Pump Specs GP6124 page 3 Exploded View page 4 Parts List Kits page 5 Pump Specs GP6128 page 6 Repair Instructions page 7 Torque Specifications page 7 Dimensions back page Updated 3 98 Warranty Information 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 installa tion 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 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 blockag
5. conditions invalidates the warranty 1 Prior to initial operation add oil to the crank case so that oil level is between the two lines on the oil dipstick DO NOT OVERFILL SAE 80 Industrial Gear oil may be used 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 GP6124 Volume Up to 12 8 GPM Discharge Pressure Up to 5800 PSI Up to 800 RPM Inlet Pressure Up to 90 PSI Plunger Diameter Plunger Stroke Crankshaft Diameter Key Width Crankshaft Mounting Either side Shaft Rotation Top of pulley towards manifold Temperature of Pumped Fluids Up to 140 F Inlet Ports 2 1 1 2 NPT Discharge Ports 2 1 NPT Crankcase Oil Capacity Fluid End Material 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 Positive inlet
6. e or the use of a shut off gun 4 Use of a dampener is necessary to minimize pulsation at drive elements plumbing connec tions and other system areas The use of a dampener with Giant Industries Inc pumps is optional although recommended by Giant Industries Inc to further reduce system pulsa tion 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 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 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 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
7. ents for the pump Gas engine power outputs must be approximately twice the pump power requirements shown above We recommend a 1 15 service factor be specified when selecting an electric motor as the power source To compute specific pump horsepower requirements use the following formula HP GPM X PSD 1400 GP6128 HORSEPOWER REQUIRMENTS RPM GPM 1000 PSI 2000 PSI 3000 PSI 4000 PS 400 18 0 6 2 12 4 18 6 24 8 500 15 8 7 8 15 6 24 2 31 1 600 13 5 9 3 18 6 27 9 37 2 700 11 3 10 9 21 8 32 7 43 5 800 9 0 12 4 24 9 37 2 49 6 REPAIR INSTRUCTION GP6124 amp GP6128 To Check Valves Loosen plugs 56 and take out complete valve 51 with a slide hammer provided with pump With a bent piece of wire take out o rings 56A located between the suction and discharge valves To dismantle the valves carefully tap the valve plate 51B with a bolt until the valve seat 51A is pushed out of the spacer pipe 51D Check the sealing surfaces and replace all worn parts Check the o rings When reinstalling the valve particular care must be taken so that the o rings sit properly in their fittings in the valve casing Tighten the plugs 56 to 160 ft Ibs To Check Seals and Plunger Pipe Loosen nuts 49A and remove the pump head Separate the plunger connection 36 from the crosshead assembly 25 by means of two open end wrenches size 22mm and 27mm Pull seal sleeves 40 out of their fitti
8. necting rods 24 and push connecting rod halves as far into the crosshead guide as possible IMPORTANT Connecting rods are marked for identification Do no twist con rod halves Con rod is to be reinstalled in the same position on shaft journals Check surfaces of connecting rod and crankshaft 22 Take out bearing cover to one side and push out crankshaft taking particular care that the connecting rod does not get bent 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 1mm maximum 0 15mm by means of fitting disc 20A Shaft should tum easily with little clearance Tighten inner hexagon screws 10 to 355 in Ibs IMPORTANT Connecting rod has to be able to be slightly moved sidewise at the stroke journals GP6124 amp GP6128 TORQUE SPECIFICATIONS Position Item Description Torque Amount 10 13133 Inner Hexagon Screw 355 in lbs 36 13219 Plunger Connection 33 ft lbs 38 07131 Tensioning Screw 355 in lbs 49A 13160 Nut Valve Casing 103 ft Ibs 56 13371 Tensioning Plug 160 ft Ibs 7 GP6124 amp Filling Key Cenlring Hale GP6128 DIMENSIONS Discharge Connection Suclion Coannectian 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
9. ngs in the crankcase 1 Take seal case 41 out of seal sleeve 40 Examine plunger 37 guide ring v sleeve 44 and seals 42 43 45 Check o rings 41A and 41C and support rings 41B and 41D Replace worn parts Grease seals with Silicone before reinstalling Replace plunger 37 and tighten to 355 in lbs IMPORTANT Do not loosen the three plunger screws 36 before the valve casing 50 has been removed otherwise the tension screw 38 for GP6128 or plunger 37 for GP6124 could hit against the spacer pipe 51D when the pump is being turned For the GP6128 the seal unit 43 44 44A is loaded by spring 42 Seal life can be increased if the loading allows for a little leakage This assists lubrication and keeps the seals cool It is therefore not necessary to replace the seals before the leakage becomes too heavy and causes output and operating pressure to drop When reassembling tighten plunger 37 to 33 ft Ibs Check o rings on seal case 41 Clean surfaces of seal sleeves in gear box and sealing surfaces of valve casing Push valve casing carefully onto o rings of seal case and centering studs 49C Tighten nuts 49A to 103 ft Ibs To Disassemble Gear End Take out plunger and seal sleeves as described above Drain oil After removing the circlip ring 33B pry 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 con
10. pressures are recommended HORSEPOWER RATINGS The rating shown are the power requirements for the pump Gas engine power outputs must be approximately twice the pump power requirements shown above We recommend a 1 15 service factor be specified when selecting an electric motor as the power source To compute specific pump horsepower requirements use the following formula HP GPM X PSD 1400 GP6124 HORSEPOWER REQUIRMENTS RPM GPM 1000 PSI 2500 PSI 4000 PSI 5800 PSI 400 6 4 4 6 11 4 18 3 26 5 500 8 0 5 7 14 3 22 9 33 2 600 9 6 6 9 17 2 27 5 39 8 700 11 2 8 0 20 0 32 0 46 4 800 12 8 9 2 22 9 36 6 53 1 Exploded View GP6124 amp GP6128 PART 13200 13000 13201 13202 13203 01009 13133 13134 07109 07182 13204 13205 08055 13206 13207 13208 13209 08213 13211 13212 13213 13214 07225 0100 13136 07622 07623 06118 13215 13216 07721 13217 13218 13219 07125 13397 13220 07131 07755 Plunger Packing Kits GP 6124 Qty Part GP6124 amp GP6128 PARTS LIST DESCRIPTION Crankcase Oil Filler Plug Assembly Crankcase Cover O Ring 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 Hexagon Screw G
11. rommet Washer Eye Bolt Radial Shaft Seal Grooved Ring Seal Retainer O Ring Circlip Flinger Plunger Connection GP6128 Centering Sleeve GP6128 Plunger Pipe GP6124 Plunger Pipe GP6128 Tensioning Screw GP6128 Copper Ring GP6128 Scones ka Fa NN AA b b FA Lin ry D L Li Loi ai Lal ai ad Lal Loi ai Lal Lad a F Bh Fa Lal a Lal eR Fa Fa ITEM 40 40 41 41 41A 41A 41B 41B 41C 41D 42 42 43 43 44 44 45 45 46 49 PART 13398 13221 13399 13222 12055 07721 07693 13223 12055 07693 13400 07173 07685 13368 07718 13401 13369 13370 13238 13228 07644 13159 13160 13162 13229 07064 13130 07063 07062 07066 06077 07150 06266 06078 13230 07661 13044 13045 13362 13358 DESCRIPTION Seal Sleeve GP6124 Seal Sleeve GP6128 Seal Case GP6124 Seal Case GP6128 O Ring GP6124 O Ring GP6128 Support Ring GP6124 Support Ring GP6128 O Ring GP6128 Support Ring GP6128 Grooved Ring GP6124 Tension Spring GP6128 Packing GP6124 Support Ring GP6128 Support Ring GP6124 Guide Ring GP6124 V Sleeve GP6128 Pressure Ring GP6128 Leakage Seal GP6124 Leakage Seal GP6128 Threaded Pipe Stud Bolt Nut Centering Stud Valve Casing Valve Seat Valve Plate GP6124 Valve Plate GP6128 Valve Spring Spacer Pipe Tensioning Plug O Ring Support Ring Spring Spacer Ring Copper Ring Plug Plug Disc Crankshaft Inner
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