Giant GP6140-4000 User's Manual
Contents
1. 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 Reassemble in reverse order Regulate axial bearing clearance minimum 0 1mm maximum 0 15mm by means of fitting disc 20A Shaft should turn easily with little clearance Tighten inner hexagon screws 24 to 355 in lbs IMPORTANT Connecting rod has to be able to be slightly moved sidewise at the stroke journals GP6140 4000 and GP6145 4000 TORQUE SPECIFICATIONS Position Item Description Torque Amount 24 06896 Inner Hexagon Screw 355 in lbs 38 12554 Tensioning Screw 33 ft Ibs 49A 06958 Nut Valve Casing 103 ft lbs 56 05171 Tensioning Plug 160 ft Ibs GP6140 4000 amp GP6145 4000 DIMENSIONS Inches mm oe E Discharge 2x 1 1 4 BSP 3 2680 m1290 7 MO ao Sg L E Inlet 3x 2 1 2 BSP 0 00255 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 ca2. 13297 Tension Spring 3 43 12558 Sleeve Support Ring GP6140 4000 3 43 13395 Sleeve Support Ring GP6145 4000 3 44 12559 Sleeve GP6140 4000 6 44 13294 Sleeve GP6145 4000 6 44A 12560 Pressure Ring GP6140 4000 3 44A 13292 Pressure Ring GP6145 4000 3 45 12561 Leakage Seal GP6140 4000 3 45 13290 Leakage Seal GP6145 4000 3 45A 12562 Spacer Disc GP6140 4000 only 3 46 05169 Threaded Pipe 3 49 13159 Stud Bolt 8 49A 06958 Hexagon Nut 8 49C 13162 Centring Stud 2 50 12563 Valve Casing 1 Ki 05164 Valve Assembly 51A D 6 SIA 12564 Valve Seat 6 SIB 12565 Valve Plate 6 SIC 12566 Valve Spring 6 SID 12567 Spacer Pipe 6 2 05166 O Ring for 51 6 56 05171 Plug 3 57 05167 O Ring for 56 3 59 06807 Copper Seal for 12 1 Ku 13151 Plug G 1 1 4 1 6l 12568 Plug G 2 1 2 1 6 13362 Disc for Crankshaft 1 67 13358 Hexagon Screw 1 17245 Gear Assembly 2x12 1 34 49 49 A C 66 67 1 17746 Pump Head Assembly 3x12 50 61 1 17247 Plunger Replacement Kit GP6140 4000 1 17248 Plunger Replacement Kit GP6140 4000 1 GP6140 4000 amp GP6145 4000 REPAIR KITS Plunger Packing Kits GP 6140 4000 09622 Item Part Description Qty 41A 07721 O Ring 3 41C 13141 O Rin 3 44 12559 Sleeve 6 44A 12560 Pressure Ring 3 45 12561 Grooved Ring 3 GP6145 4000 09623 Item Part Description Qty 41A 07721 O Ring 3 41C 13141 O Rin 3 44 13294 Sleeve 6 44A 13292 Pressure Ring 3 45 12561 Grooved Ring 3 Valve Assembly Kit 09624 Ttem Part Descrip
3. 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 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 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 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 recom mended 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 w
4. sleeves and grooved ring 45A in GP6140 4000 only Check the o rings 41A and 41C 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 could hit against the spacer pipe 51D when the pump is being turned For the pumps the seal unit 43 44 44A is loaded by a 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 lbs 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 lbs 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 and 33A and surfaces of crosshead Remove crankcase cover 4 Loosen inner hexagon screws on the connecting rods 24 and push connecting rod halves as far into the crosshead guide as possible IMPORTANT Connecting rods are marked for identification
5. 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 PSI 1400 GP6145 4000 HORSEPOWER REQUIREMENTS RPM GPM 500 PSI 1000 PSI 1500 PSI 1740 PSI 600 34 9 12 5 249 374 433 GP6140 4000 amp GP6145 4000 REPAIR INSTRUCTIONS 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 52 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 lbs 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 fittings in the crankcase 1 Take seal case 41 out of seal sleeve 40 Examine plunger 37 and
6. Triplex Ceramic Plunger Pump Operating Instructions Manual Models GP6140 4000 amp GP6145 4000 Contents Installation Instructions page 2 Pump Specs GP61 40 4000 page 3 Exploded View page 4 Parts List Kits page 5 Pump Specs GP61 45 4000 page 6 Repair Instructions page 7 Torque Specifications page 7 Dimensions back page 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
7. bees stusteasbongesnire ness Either side Shatt Rotation enee geseet deed Top of pulley towards manifold Temperature of Pumped Fluids max 140 nb 60 C Talet POr sssccesccsecestoececedtuentedivederses S Segu deeg eege end eeh ees ess wee 2 1 1 2 BSP Discharge Ports ase pererin enee eege 2 1 BSP KEE 309 IDS sessessveestesesssssosstesivesteastess 140 Kg Crankcase Oil Capacity s s s Wh VG E 4 2 Liters Fluid End Material sesser ieina Stainless Steel 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 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 PSI 1400 GP6140 4000 HORSEPOWER REQUIREMENTS DEM GEM 500 PSI 1000 PSI 1500 PSI 2175 PSI 400 18 4 66 131 197 285 600 27 5 98 197 295 428 Exploded View GP6140 4000 amp GP6145 4000 Important The stainless steel valve plugs 56 can seize when being taken out of the valve casing To release tension beforehand strike the plugs 1 2 times with a steel hammer on the top before removing them Coat threads with anti seize e g ProPack 550 before ref
8. ith any of these conditions invalidates the warranty 1 Prior to initial operation add oil to the crankcase so that oil level is between the two lines on the oil dipstick DO NOT OVER FILL Use Giant Recommended Oil p n 01154 which is equivalent to SAE 85 90W Industrial Grear Lube 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 tem peratures NOTE Contact Giant Industries for Service School Information Phone 419 531 4600 2 Specifications Model GP6140 4000 Ken 360 7 GPM RE 139 L min Discharge Pressure eceeeeeeeseeneee ZU TD PSM oisein 150 Bar Speed EEN 800 RPM Inlet Pressure Max encecissoiiosenss VAS UPS EE 10 Bar Plunger Diameter Seeerei edd 40mm Plunger Stroke wcccteesseetietssecistisevcsctenesscees WOOF A 48mm Crankshaft Diameter eege 45mm Kee Width o sitsssisiciisciesvssssosvsssccsesiecceaen ace UE wes sescseti seeives sheevsi tdecesivesivezace 12mm Crankshaft Mount sc tcsseicsscscecstostesstnterndetavsleieoteed
9. itting IFM PART 1 13200 2 13000 4 13201 5 13202 8 06894 9 01009 10 22706 11 06725 12 7109 0400 13 07182 14 12549 15 13205 16 08055 20 13206 20A 13207 21 13208 22 06895 23 08213 24 06896 25 12550 28 06898 30 13214 30A 07225 0100 30B 13136 30C 08280 31 07623 32 06118 32A 13216 33 13216 0100 33A 07721 33B 13217 0100 33C 12551 34 13218 36 12552 36A 07125 37 12553 37 05157 38 12554 39 07755 0100 40 12555 40 12556 41 12557 GP6140 4000 amp GP6145 4000 PARTS LIST DESCRIPTION Crankcase Oil Filler Plug Assy Crankcase Cover O RIng for 4 Oil Dipstick O Ring for 8 Hexagon Screw Spring Washer Drain Plug Seal for 12 Bearing Cover Radial Shaft Seal O Ring for 14 Taper Roller Bearing Fitting Disc Shaft Protector Crankshaft Fitting Key Connecting Rod Assy Crosshead Assy Crosshead Pin Cover Plate Hexagon Screw Grommet Disc Eye Bolt Radial Shaft Seal Grooved Ring Seal Retainer O Ring for 33 Circlip for 33 Fitting Disc Oil Scraper Plunger Connection Centering Sleeve Plunger Pipe GP6140 4000 Plunger Pipe GP6145 4000 Tensioning Screw Copper Ring Seal Sleeve GP6140 4000 Seal Sleeve GP6145 4000 Seal Case T n LA GA 4 L Gi 4 Li L Lu La L L La Gi L Lu ra BP PR WW WR RR TEM PART DESCRIPTION QTY 41A 07721 O Ring for 41 3 41B 13223 Support Ring for 41A 3 41C 13141 O Ring for 41 3 41D 07693 Support Ring for 41C 3 42
10. nty consideration Call 419 531 4600 or fax 419 531 6836 to obtain an HOA 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 EXPRESS OR IMPLIED INCLUDING WITHOUT LIMITATION ANY WARRAN 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 PHONE 419 531 4600 FAX 419 531 6836 www giantpumps com Copyright 2007 Giant Industries Inc 04 07 GP6140 4000_GP6145 4000 PMD
11. r 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 Oa Pp PY 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 warra
12. tion Qty SIA 12564 Valve Seat 6 51B 12565 Valve Plate 6 SIC 12566 Valve Spring 6 32 05166 O Ring 6 37 05167 O Ring 6 Oil Seal Kit 09625 Ttem Part Description Qty 32 06118 Radial Shaft Seal 3 33A 07721 O Ring 3 Specifications Model GP6145 4000 VOLUME e cdecesseseseseieeivisecsessed TEE e 46 5 GPM E 175 9 L min Discharge Pressure seeen P74 O PSU crisscross 120 Bar SS POO E 800 RPM Inlet Pressure MaX uossiinorisssserisserssrsee 145 TE 10 Bar Plunger Diameters WDD esscccuesssccsoetadecteesdccssvtessets0i ce 45mm Plunger Stroke csicescscsticsstecssavecteusssetescees WOO eered pen eet evaeteants 48mm Crankshaft Diameter T E 45mm Key Width upresnenia anan UE ereere E ENE 12mm Crankshaft Mounting siss sic cseiiccessesicdsstscicesssectesvaccosseeicedesidacevasdeseeses sevtsentexe Either side Shalt Rotations ien eener sasesteestencessnnedssente omens GEES Top of pulley towards manifold Temperature of Pumped Fluids max IAU 60 C Inlet POTIS 11608 EES ERENNERT 2 1 1 2 BSP Discharge Ports 22 ccccdess cevsssvasstesescviwesvestansteceazticeeesstuecssves ccvsex heeteuaneesvaasees 2 1 BSP KE DODDS E E cistectiane 140 Kg Crankcase Oil Capacity 0 0 cece MANGAL a eege Seeer Geeece 4 2 Liters Pluid End Materialiosios taaa e e E RE Stainless Steel 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 HORSEPOWER RATINGS
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