Giant Water Pump GP6140 4000 User Manual

Triplex Ceramic  
Plunger Pump  
OperatingInstructions/  
Manual  
Models  
GP6140-4000 & GP6145-4000  
Contents:  
Installation Instructions:  
Pump Specs.(GP6140-4000):  
Exploded View:  
page 2  
page 3  
page 4  
Parts List / Kits:  
page 5  
Pump Specs.(GP6145-4000):  
Repair Instructions:  
Torque Specifications:  
Dimensions:  
page 6  
page 7  
page 7  
back page  
back page  
WarrantyInformation:  
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Specifications  
Model GP6140-4000  
Volume ....................................................36.7 GPM .................................. 139 L/min  
Discharge Pressure ................................ 2175 PSI .................................... 150 Bar  
Speed .......................................................................................................... 800 RPM  
Inlet Pressure (max.) .............................. 145 PSI ...................................... 10 Bar  
Plunger Diameter....................................1.57” .......................................... 40mm  
Plunger Stroke ........................................1.89” .......................................... 48mm  
Crankshaft Diameter .............................. 1.78” .......................................... 45mm  
Key Width ............................................... 0.47” .......................................... 12mm  
Crankshaft Mounting .................................................................................. Either side  
Shaft Rotation ................................................................................ Top of pulley towards manifold  
Temperature of Pumped Fluids (max). ...140 oF ........................................ 60 oC  
Inlet Ports ................................................................................................... (2) 1-1/2" BSP  
Discharge Ports .......................................................................................... (2) 1" BSP  
Weight .....................................................309 lbs. ...................................... 140 Kg  
Crankcase Oil Capacity ..........................1.1 Gal. ...................................... 4.2 Liters  
Fluid End Material....................................................................................... 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  
RPM GPM 500 PSI 1000 PSI 1500 PSI 2175 PSI  
400  
500  
600  
700  
800  
18.4  
22.9  
27.5  
32.1  
36.7  
6.6  
8.2  
9.8  
11.5  
13.1  
13.1  
16.4  
19.7  
22.9  
26.2  
19.7  
24.6  
29.5  
34.4  
39.3  
28.5  
35.6  
42.8  
49.9  
57.0  
3
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Exploded View - GP6140-4000 & 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 refitting.  
4
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GP6140-4000 & GP6145-4000 PARTS LIST  
ITEM PART  
DESCRIPTION  
Crankcase  
Oil Filler PlugAssy  
Crankcase Cover  
O-RIng for 4  
Oil Dipstick  
O-Ring for 8  
Hexagon Screw  
Spring Washer  
QTY.  
1
1
1
1
1
1
12  
12  
3
2
2
2
2
2
1-5  
1
1
1
3
3
3
1
4
4
4
1
3
3
3
3
3
3
3
3
ITEM PART  
41A 07721  
41B 13223  
41C 13141  
41D 07693  
DESCRIPTION  
O-Ring for 41  
Support Ring for 41A  
O-Ring for 41  
Support Ring for 41C  
Tension Spring  
Sleeve Support Ring  
(GP6140-4000)  
Sleeve Support Ring  
(GP6145-4000)  
Sleeve ((GP6140-4000)  
Sleeve (GP6145-4000)  
Pressure Ring (GP6140-4000)  
Pressure Ring (GP6145-4000)  
Leakage Seal (GP6140-4000)  
Leakage Seal (GP6145-4000)  
Spacer Disc (GP6140-4000) only 3  
Threaded Pipe  
Stud Bolt  
Hexagon Nut  
Centring Stud  
Valve Casing  
ValveAssembly (51A-D)  
Valve Seat  
Valve Plate  
Valve Spring  
Spacer Pipe  
O-Ring for 51  
Plug  
QTY.  
1
2
4
5
8
9
10  
11  
12  
13  
14  
15  
16  
20  
13200  
13000  
13201  
13202  
06894  
01009  
22706  
06725  
3
3
3
3
3
42  
43  
13297  
12558  
3
43  
13395  
7109-0400 Drain Plug  
3
6
6
3
3
3
3
07182  
12549  
13205  
08055  
13206  
Seal for 12  
44  
44  
12559  
13294  
Bearing Cover  
Radial Shaft Seal  
O-Ring for 14  
Taper Roller Bearing  
Fitting Disc  
Shaft Protector  
Crankshaft  
44A 12560  
44A 13292  
45  
45  
12561  
13290  
20A 13207  
21  
22  
23  
24  
25  
28  
30  
13208  
06895  
08213  
06896  
12550  
06898  
13214  
45A 12562  
46  
49  
05169  
13159  
3
8
8
2
1
6
6
6
6
6
6
3
3
1
1
1
1
1
Fitting Key  
Connecting Rod Assy  
Crosshead Assy  
Crosshead Pin  
Cover Plate  
49A 06958  
49C 13162  
50  
51  
12563  
05164  
30A 07225-0100 Hexagon Screw  
30B 13136  
30C 08280  
51A 12564  
51B 12565  
51C 12566  
51D 12567  
Grommet  
Disc  
Eye Bolt  
Radial Shaft Seal  
Grooved Ring  
31  
32  
07623  
06118  
52  
56  
57  
59  
60  
61  
66  
67  
05166  
05171  
05167  
06807  
13151  
12568  
13362  
13358  
17245  
32A 13216  
33  
33A 07721  
33B 13217-0100 Circlip for 33  
13216-0100 Seal Retainer  
O-Ring for 56  
Copper Seal for 12  
Plug G 1 1/4  
O-Ring for 33  
33C 12551  
Fitting Disc  
Oil Scraper  
Plug G 2 1/2  
34  
36  
13218  
12552  
Disc for Crankshaft  
Hexagon Screw  
GearAssembly  
(2x12/1-34/49/49A-C/66/67)  
Pump Head Assembly  
(3x12/50-61)  
Plunger Replacement Kit  
(GP6140-4000)  
Plunger Replacement Kit  
(GP6140-4000)  
Plunger Connection  
Centering Sleeve  
Plunger Pipe (GP6140-4000)  
Plunger Pipe (GP6145-4000)  
Tensioning Screw  
36A 07125  
3
3
3
3
3
3
3
3
37  
37  
38  
39  
40  
40  
41  
12553  
05157  
12554  
1
1
1
1
17746  
17247  
17248  
07755-0100 Copper Ring  
12555  
12556  
12557  
Seal Sleeve (GP6140-4000)  
Seal Sleeve (GP6145-4000)  
Seal Case  
GP6140-4000 & GP6145-4000 REPAIR KITS  
Valve Assembly Kit - #09624  
Plunger Packing Kits  
GP 6140-4000  
# 09622  
Description  
O-Ring  
Item  
51A  
51B  
51C  
52  
Part #  
12564  
12565  
12566  
05166  
05167  
Description  
Valve Seat  
Valve Plate  
Valve Spring  
O-Ring  
Qty.  
6
6
6
6
Item  
41A  
41C  
44  
44A  
45  
Part #  
07721  
13141  
12559  
12560  
12561  
Qty.  
3
3
6
3
O-Rin  
Sleeve  
Pressure Ring  
Grooved Ring  
# 09623  
Description  
O-Ring  
57  
O-Ring  
6
3
GP6145-4000  
Oil Seal Kit - 09625  
Item  
32  
Item  
41A  
41C  
44  
44A  
45  
Part #  
07721  
13141  
13294  
13292  
12561  
Qty.  
3
3
Part #  
06118  
07721  
Description  
Radial Shaft Seal  
O-Ring  
Qty.  
3
O-Rin  
Sleeve  
33A  
3
6
Pressure Ring  
Grooved Ring  
3
3
5
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Specifications  
Model GP6145-4000  
Volume ....................................................46.5 GPM .................................. 175.9 L/min  
Discharge Pressure ................................ 1740 PSI .................................... 120 Bar  
Speed .......................................................................................................... 800 RPM  
Inlet Pressure (max.) .............................. 145 PSI ...................................... 10 Bar  
Plunger Diameter....................................1.77” .......................................... 45mm  
Plunger Stroke ........................................1.89” .......................................... 48mm  
Crankshaft Diameter .............................. 1.78” .......................................... 45mm  
Key Width ............................................... 0.47” .......................................... 12mm  
Crankshaft Mounting .................................................................................. Either side  
Shaft Rotation ................................................................................ Top of pulley towards manifold  
Temperature of Pumped Fluids (max). ...140 oF ........................................ 60 oC  
Inlet Ports ................................................................................................... (2) 1-1/2" BSP  
Discharge Ports .......................................................................................... (2) 1" BSP  
Weight .....................................................309 lbs. ...................................... 140 Kg  
Crankcase Oil Capacity ..........................1.1 Gal. ...................................... 4.2 Liters  
Fluid End Material....................................................................................... 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  
GP6145-4000 HORSEPOWER  
REQUIREMENTS  
RPM GPM 500 PSI 1000 PSI 1500 PSI 1740 PSI  
400  
500  
600  
700  
800  
23.3  
29.1  
34.9  
40.7  
46.5  
8.3  
16.6  
20.8  
24.9  
29.1  
33.2  
24.9  
31.1  
37.4  
43.6  
49.8  
28.9  
36.1  
43.3  
50.6  
57.8  
10.4  
12.5  
14.5  
16.6  
6
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GP6140-4000 & 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 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. 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#  
06896  
12554  
06958  
05171  
Description  
Torque Amount  
355 in.-lbs.  
24  
38  
49A  
56  
Inner Hexagon Screw  
Tensioning Screw  
Nut, Valve Casing  
Tensioning Plug  
33 ft.-lbs.  
103 ft.-lbs.  
160 ft.-lbs.  
7
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GP6140-4000 & GP6145-4000 DIMENSIONS - Inches (mm)  
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 car wash applications, the discharge manifolds  
willneverfail,period.Iftheyeverfail,wewillreplacethemfreeofcharge.Ourotherpump  
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.  
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.  
04/07GP6140-4000_GP6145-4000.PMD  
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