Giant GP6145 3100 Triplex Ceramic Plunger Pump Operating Instructions/Manual

Model
GP6145-3100
Triplex Ceramic
Plunger Pump
Operating Instructions/
Manual
Contents:
Installation Instructions:
Pump Specifications:
Exploded View:
Parts List / Kits:
Repair Instructions:
Torque Specifications:
Dimensions:
Warranty Information:
page 2
page 3
page 4
page 5
page 6
page 6
page 7
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.
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
1400 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
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 chart on page 3.
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 the
crankcase so that oil level is between the two
lines on the oil dipstick. DO NOT OVERFILL.
Use Giant Recommended Oil (p/n 01154),
which is equivalent to SAE 85-90W Industrial
Gear 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 from
Giant Industries, Inc. before operating.
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 GP6145-3100
Volume .................................................... 46.5 GPM .................................. 175.9 L/min
Discharge Pressure ................................ 1740 PSI .................................... 120 bar
Crankshaft Speed ....................................................................................... 800 RPM
Inlet Pressure (max.) .............................. Up to 90 PSI .............................. 6.2 bar
Plunger Diameter .................................... 1.77” .......................................... 45mm
Plunger Stroke ........................................ 1.89” .......................................... 48mm
Crankshaft Diameter .............................. 1.65” .......................................... 42mm
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) 1-1/4" BSP
Discharge Ports .......................................................................................... (2) 1" BSP
Weight ..................................................... 309 lbs. ...................................... 140 Kg
Crankcase Oil Capacity .......................... 1.1 Gal. ...................................... 4.2 Liters
Fluid End Material ....................................................................................... Aluminum-Bronze-Nickle
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) / 1450
GP6145-3100 HORSEPOWER
REQUIREMENTS
RPM
400
500
600
700
800
GPM
23.3
29.1
34.9
40.7
46.5
500 PSI 1000 PSI 1500 PSI 1740 PSI
8.0
16.1
24.1
28.0
10.0
20.1
30.1
34.9
12.0
24.1
36.1
41.9
14.0
28.1
42.1
48.8
16.0
32.1
48.1
55.8
3
Exploded View - GP6145-3100
4
GP6145-3100 PARTS LIST
ITEM
1
2
4
5
8
9
10
11
12
13
14
15
16
20
20A
21
22
23
24
25
28
30
30A
30B
30C
31
32
33
33A
33B
33C
34
36
37
38
39
40
PART
13200
13000
13201
13202
06894
01009
22706
06725
07109-0400
07182
12549
07877
08055
13206
13207
13208
06895
08213
06896
06897
06898
13214
07225-0100
13136
08280
07623
06118
13216-0100
07721
13217-0100
12551
13218
05156-0100
05157
05158-0100
07755-0100
05159-0100
DESCRIPTION
Crankcase
Oil Filler Plug Assy
Crankcase Cover
O-Ring for 4
Oil Dipstick
O-Ring for 8
Hexagon Screw
Spring Washer
Drain Plug
Copper Seal Ring, 1/2”
Bearing Cover
Radial Shaft Seal
O-Ring for 14
Taper Roller Bearing
Fitting Disc
Shaft Protector
Crankshaft
Fitting Key
Connecting Rod Assembly
Crosshead Assembly
Crosshead Pin
Cover Plate
Hexagon Screw
Grommet
Disc
Eye Bolt
Radial Shaft Seal
Seal Retainer
O-Ring for 33
Clipring for 33
Fitting Disc
Oil Scraper
Plunger Connection
Plunger Pipe
Tensioning Screw
Gasket, Steel, 1/4”
Seal Sleeve
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
3
3
3
ITEM
41
41A
41C
42
43
44
44A
46
47
48
49
49A
49C
50
51
51A
51B
51C
51D
51E
52
56
57
59
60
61
66
67
68
69
70
71
72
73
74
75
PART
05160-0100
07721-0001
13141-0001
13297
13395
13294
13293
05057
05161-0100
05474
13159
06958
13162
12563-3000
05164-0100
12564-0100
12565-0100
12566
12567-0100
05475
05166-0001
05171-0100
05167-0001
06807
13151-0100
12568
13362
13358
06588
07204-0100
06768
05476
05477
05478
05479
05480
DESCRIPTION
QTY.
Seal Case
3
O-Ring for 41, Viton
3
O-Ring for 41, Viton
3
Tension Spring, red
3
Sleeve Support Ring
3
Sleeve
6
Pressure Ring
3
Compact Ring
3
Support Ring
3
Clipring
3
Stud Bolt
8
Hexagon Nut
8
Centering Stud
2
Valve Casing
1
Valve Assembly (51A-E)
6
Valve Seat
6
Valve Plate
6
Valve Spring
6
Spacer Pipe
6
Valve Spring Guide
6
O-Ring for 51, Viton
6
Tension Plug
3
O-Ring for 56, Viton
3
Steel Seal for 12
1
Plug, 1-1/4” BSP
1
Plug, 2-1/2” BSP
1
Disc for Crankshaft
1
Hexagon Screw
1
Screw-in Pipe Connection
5
Steel Seal Ring
5
Elbow for Drip Return
3
Elbow w/Nuts for Drip Return 2
Leakage Pipe, Curved
1
Pipe Bend, 180 Deg.
1
Pipe Bend, 90 Deg.
1
Leakage Pipe. Straight
1
GP6145-3100 REPAIR KITS
Plunger Packing Kits - #09632
Valve Assembly Kit - #09633
Item
41A
41C
44
44A
46
Item
51A
51B
51C
52
57
Part #
07721-0001
13141-0001
13294
13293
05057
Description
O-Ring
O-Ring
Sleeve
Pressure Ring
Compact Ring
Qty.
3
3
6
3
3
Oil Seal Kit - #09625
Item
32
33A
Part #
06118
07721
Description
Radial Shaft Seal
O-Ring
Qty.
3
3
5
Part #
12564-0100
12565-0100
12566
05166
05167
Description
Valve Seat
Valve Plate
Valve Spring
O-Ring
O-Ring
Qty.
6
6
6
6
3
GP6145-3100 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.(220 N-M)
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
(44). Check the o-rings (41A and 41C). Replace worn parts. Grease seals with Silicone before reinstalling.
Replace plunger (37) and tighten tension screw (38) to 29 ft-lbs.(40 N-M)
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.(45 N-M)
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.(140 N-M)
To Disassemble Gear End
Take out plunger and seal sleeves as described above. Drain oil. After removing the clipring (33B), pry out
seal retainer (33) with a screw driver. Check seals (32) and surfaces of crosshead (25). 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 not twist conn-rod halves. Conn-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
29 ft-lbs.(40 N-M)
IMPORTANT: Connecting rod has to be able to be slightly moved sidewise at the stroke journals.
GP6145-3100 TORQUE SPECIFICATIONS
Position
Item#
24
38
49A
56
06896
05158-0100
06958
05171-0100
Description
Torque Amount
Inner Hexagon Screw
Tensioning Screw
Nut, Valve Casing
Tensioning Plug
6
29 ft-lbs.
33 ft-lbs.
103 ft-lbs.
220 ft-lbs.
GP6145-3100 DIMENSIONS - Inches (mm)
7
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 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, 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
PHONE (419) 531-4600, FAX (419) 531-6836, www.giantpumps.com
 Copyright 2008 Giant Industries, Inc.
10/08 GP6145-3100.PMD