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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