Triplex Ceramic
Plunger Pump
Operating Instructions/
Repair and Service
Manual
Model
GP6132
Contents:
Installation Instructions:
Pump Specs:
Exploded View:
page 2
page 3
page 4
page 5
page 5
page 6
page 7
Parts List / Kits:
Torque Specifications:
Repair Instructions:
Troubleshooting Chart:
Recommended Spare Parts:
Dimensions:
Warranty Information:
page 7
back page
back page
Updated 8/07
Download from Www.Somanuals.com. All Manuals Search And Download.
Specifications
Model GP6132
U.S. .............................. Metric
Volume................................................................. 23.5 GPM ..................... 88.9 LPM
Discharge Pressure .............................................. 3045 PSI ....................... 210 BAR
Speed .......................................................................................................... 800 RPM
Inlet Pressure ....................................................... -4.35 to 145 PSI
....................
-0.3 to 10 BAR
Plunger Diameter ................................................. 1.26” ............................. 32mm
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 ........................... Up to 140 oF ................. 60 oC
Inlet Ports ................................................................................................... (2) 1-1/4" BSP
Discharge Ports........................................................................................... (2) 2-1/2" BSP
Weight.................................................................. 309 lbs. ......................... 140 kg
Crankcase Oil Capacity ....................................... 1.1 Gal.......................... 4.2 Liters
Fluid End Material ..................................................................................... Bronze
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 approxi-
mately 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
GP6132 HORSEPOWER REQUIREMENTS
RPM
400
500
600
700
800
GPM
11.8
14.7
17.6
20.6
23.5
1000 PSI
8.1
1500 PSI
12.2
2500 PSI
20.3
3045 PSI
24.7
10.1
12.2
14.2
16.2
15.2
18.2
21.3
24.3
25.3
30.4
35.5
40.5
30.8
37.0
43.2
49.4
3
Download from Www.Somanuals.com. All Manuals Search And Download.
EXPLODED VIEW - GP6132
4
Download from Www.Somanuals.com. All Manuals Search And Download.
GP6132 SPARE PARTS LIST
ITEM PART
DESCRIPTION
Crankcase
QTY.
1
ITEM PART
DESCRIPTION
Plunger Connection
Centering Sleeve
Plunger Pipe
Tensioning Screw
Copper Ring
QTY.
3
3
3
3
3
3
3
3
3
3
3
3
3
6
3
3
3
8
8
2
1
6
6
6
6
6
3
3
1
1
1
1
1
2
4
5
8
9
13200
13000
13201
13202
06894
01009
13133
06725
07109
07182
12549
13205
08055
13206
13207
13208
06895
08213
06896
06897
06898
13214
36
36A
37
38
39
13219
07125
13022
05168
07755
05192
13222
07721
13223
12055
07693
07173
05176
06096
05174
13360
05169
13159
13160
13162
05191
12564
12565
12566
12567
05166
05171
05167
07661
13151
13171
13362
13358
Oil Filler Plug Assy
Crankcase Cover
O-Ring for 4
1
1
1
Oil Dipstick
O-Ring for 8
1
1
40
41
Seal Sleeve
Seal Case
10
11
12
13
14
15
16
20
20A
21
22
23
24
25
28
30
30A
30B
30C
31
32
32A
33
33A
33B
33C
34
Hexagon Screw
Spring Washer
Drain Plug
12
12
3
41A
41B
41C
41D
42
43
44
44A
45
46
O-Ring for 41
Support Ring for 41A
O-Ring for 41
Support Ring for 41C
Tension Spring
Sleeve Support Ring
Sleeve
Pressure Ring
Leakage Seal
Threaded Pipe
Stud Bolt
Seal for 12
2
Bearing Cover
Radial Shaft Seal
O-Ring for 14
Taper Roller Bearing
Fitting Disc
2
2
2
2
1-5
1
1
Shaft Protector
Crankshaft
Fitting Key
1
49
Connecting Rod Assy
Crosshead Assy
Crosshead Pin
Cover Plate
3
3
3
1
49A
49C
50
51A
51B
51C
51D
52
56
57
59
60
Nut
Centring Stud
Valve Casing
Valve Seat
Valve Plate
Valve Spring
Spacer Pipe
07225-0100 Hexagon Screw
4
13136
07622
07623
06118
13215
13216
07721
13217
12551
13218
Grommet
Disc
Eye Bolt
4
4
1
O-Ring for 51
Plug
Radial Shaft Seal
Grooved Ring
Seal Retainer
O-Ring for 33
Circlip for 33
Fitting Disc (not shown)
Oil Scraper
3
3
3
3
3
3
3
O-Ring for 56
Copper Seal for 12
Plug, 1-1/4” BSP
Plug, 2-1/2” BSP
Disc for Crankshaft
Hexagon Screw
61
66
67
1
GP6132 REPAIR KITS
Plunger Packing Kit # 09319
Valve Assembly Kits #09320
Oil Seal Kit # 09304
Item Part # Description
41A 07721 O-Ring
41B 13223 Support ring
41C 12055 O-Ring
Qty.
Item Part # Description
51A 12564 Valve Seat
51B 12565 Valve Plate
51C 12566 Valve Spring
Qty.
6
6
6
6
Item Part # Description
Qty.
3
3
3
3
6
6
6
3
32
06118 Radial Shaft Seal
32A 13215 Grooved Ring
33A 07721 O-Ring
3
41D 07693 Support Ring
52
57
05166 O-Ring
05167 O-Ring
44
45
06096 Sleeve
13360 Leakage Seal
3
GP6132 TORQUE SPECIFICATIONS
Position
Item#
Description
Torque Amount
10
36
38
49A
56
13133
13219
05168
13160
05171
Inner Hexagon Screw
Plunger Connection
Tensioning Screw
Nut, Valve Casing
Tensioning Plug
30 ft.-lbs.
33 ft.-lbs.
30 ft.-lbs.
103 ft.-lbs.
160 ft.-lbs.
5
Download from Www.Somanuals.com. All Manuals Search And Download.
REPAIR INSTRUCTION - GP6132
To Check Valves
1. Loosen plugs (56) and take out complete valve assemblies (51) with a slide hammer. Use a bent
to remove the o-rings (52).
piece of wire
2. 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).
3. Check the sealing surfaces and replace all worn parts. Check the o-rings.
4. When reinstalling the valve assemblies, particular care must be taken so that the o-rings (52) sit properly in their
fittings in the valve casing.
5. Tighten the plugs (56) to 160 ft.-lbs. (220 NM).
To Check Seals and Plunger Pipe
6. Loosen nuts (49A) and remove the valve casing (50).
7. Separate the plunger connection (36) from the crosshead assembly (25) by means of two open-end wrenches (size
22mm and 27mm).
8. Pull seal sleeves (40) out of their fittings in the crankcase (1).
9. Take the seal case (41) out of the seal sleeve (40).
10. Examine plunger parts (36-39) and seals (44 and 45).
11. Check o-rings (41A through 41D) and replace worn parts.
12. When replacing plunger pipe (37), tighten tension screw (38) to 30 ft.-lbs (40 NM).
13. Grease seals with Silicone before reinstalling.
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.
14. The seal unit (43, 44, 44A) is pre-tensioned 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.
15. When reassembling, tighten plunger screw (36) to 33 ft.-lbs. (45 NM).
Mounting Valve Casing
16. Check o-rings on seal case (41).
17. Clean surfaces of seal sleeves in crankcase (1) and sealing surfaces of valve casing (50).
18. Push valve casing (50) carefully onto o-rings (41A and 41B) of seal case and centering studs (49C).
19. Tighten nuts (49A) to 103 ft.-lbs. (140 NM).
To Dismantle Gear
20. As described above, take out the plunger and seal sleeves. Drain the oil.
21. After removing the circlip ring (33B), use a screw driver to lever out the seal retainer (33).
22. Check the seals (32, 32A and 33A) and surfaces of the crosshead (25).
23. Remove the crankcase cover (4) and make sure that the o-ring (5) looks good.
24. Loosen the inner hexagon screws on the connecting rods (24).
IMPORTANT: Connecting rods are marked for identification. Do not twist connecting rod halves. Connecting
rod halves are to be reinstalled in the same position and orientation onto the crankshaft (22).
25. Push the connecting rod halves as far into the crosshead guide as possible.
26. Take out the bearing cover (14) to one side and push out the crankshaft (22) taking particular care that the connecting
rod halves don’t bend
IMPORTANT: Seal (32A) must always be installed so that the seal lip on the inside diameter faces the oil. Pos-
sible axial float of the seal adaptor (33) is to be compensated for with shims (33C).
27. Reassemble in reverse order
28. Regulate axial play of the crankshaft clearance to minimum of 0.1mm, maximum of 0.15mm by means of fitting disc
(20A). The crankshaft should turn easily and with little clearance.
29. Tighten the inner hexagon screws to 30 ft-lbs. (40 NM).
IMPORTANT: The connecting rods have to be able to slightly moved sidewise at the stroke journals.
6
Download from Www.Somanuals.com. All Manuals Search And Download.
REPAIR INSTRUCTION - GP6132
PUMP SYSTEM MALFUNCTIONS
MALFUNCTION
CAUSE
REMEDY
The Pressure and/
Worn packing seals
Replace packing seals
or the Delivery Drops
Broken valve springs
Belt slippage
Worn or Damaged nozzle
Fouled discharge valve
Replace springs
Tighten or Replace belt
Replace nozzle
Clean valve assembly
Worn or Plugged relief valve on pump Clean, Reset, and Replace
worn parts
Cavitations
Check suction lines on inlet
of pump for restrictions
Unloader
Check for proper operation
Water in Crankcase
Noisy Operating
High Humidity
Worn Seals
Reduce oil change intervals
Replace seals
Worn bearings
Cavitation
Replace bearings, Refill
crankcase oil with recommended
lubricant
Check inlet lines for restrictions
and/or proper sizing
Rough/Pulsating
Operation with
Pressure Drop
Worn packing
Inlet restriction
Accumulator pressure
Replace packing
Check system for stoppage
air leaks, correctly sized
inlet plumbing to pump
Recharge/Replace accumulator
Unloader
Cavitation
Check for proper operation
Check inlet lines for restrictions
and/or proper size
Pump Pressure as
Drop at gun Rated,
Pressure
Restricted discharge plumbing
Re-size discharge plumbing to flow
rate of pump
Excessive
Leakage
Worn plungers
Replace plungers
Worn packing/seals
Adjust or Replace packing seals
Excessive vacuum
Cracked plungers
Reduce suction vacuum
Replace plungers
Inlet pressure too high
Reduce inlet pressure
High Crankcase
Temperature
Wrong Grade of Oil
Giant oil is recommended
Improper amount of oil in crankcase
Adjust oil level to proper amount
Preventative Maintenance Check List & Recommended Spare Parts List
Every
500
Every
1500
Every
3000
Hours
Hours
Hours
Check
Daily Weekly 50 Hrs.
Oil Level/Quality
Oil Leaks
X
X
Water Leaks
Belts, Puelly
Plumbing
X
X
X
Recommended Spare Parts
Oil Change
(1 gallon) p/n 01154
Plunger Seal Kit
(1 kit/pump)
Oil Seal Kit
(1 kit/pump)
X
X
X
X
Valve Repair Kit
(1 kit/pump)
X
7
Download from Www.Somanuals.com. All Manuals Search And Download.
GP6132 DIMENSIONS (mm)
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.
Thiswarrantyislimitedtorepairorreplacementofpumpsandaccessoriesofwhichthe 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 WAR-
RANTIESORMERCHANTABILITYORFITNESSFORAPARTICULARPURPOSEANDALLSUCH
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.
8/07 GP6132.PMD
Download from Www.Somanuals.com. All Manuals Search And Download.
|