Giant GP6132 User's Manual
Contents
1. 0 ai i OAPs 12mm Crankshaft Mounting Either side Shaft ROLAUOR saseta geese Top of pulley towards manifold Temperature of Pumped Fluids Up to 140 F 60 C Inlet Ports 2 1 1 4 BSP Dischatge POS sacz GA A RO O SEAS 2 2 1 2 BSP OW CL OM oss eatea aieea PZN a kla 309 DSSS 140 kg Crankcase Oil Capacity eesti ROA 4 2 Liters Fluid End Matemal oai asi esses RSA eS eR ga 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 600 176 122 182 304 37 0 EXPLODED VIEW GP6132 GP6132 SPARE PARTS LIST DESCRIPTION Plunger Connection Centering Sleeve Plunger Pipe Tensioning Screw Copper Ring Seal Sleeve Seal Case O Ring for 41 Support Ring for 41A O Ring for 41 Support Ring for 41C2. 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 s p n 01154 or the equivalent SAE 80w 90 Industrial Gear 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 temperatures NOTE Contact Giant Industries for Service School Information Phone 419 531 4600 Specifications Model GP6132 UN Metric owada A A ees ears 23 5 GPM 88 9 LPM Discharg Pressure moce zycia EA 045 PSl gt 210BAR 50860 ew A A a O O Eo 800 RPM Inlet Pressure owa zaw FEE ns 4 35 to 145 PSI 0 3 to 10 BAR 8101756710137066 7 2677 32mm 10786750086 scan MSO a AE 48mm Crankshaft Diameter 7 VOS ssl 42mm Key Wi
3. Tension Spring Sleeve Support Ring Sleeve Pressure Ring Leakage Seal Threaded Pipe Stud Bolt Nut Centring Stud Valve Casing Valve Seat Valve Plate Valve Spring Spacer Pipe O Ring for 51 Plug O Ring for 56 Copper Seal for 12 Plug 1 1 4 BSP Plug 2 1 2 BSP Disc for Crankshaft Hexagon Screw Oil Seal Kit 09304 Item Part Description 32 06118 Radial Shaft Seal 32A 33A 07721 O Ring Torque Amount 30 ft Ibs 33 ft lbs 30 ft lbs 103 ft lbs ITEM PART DESCRIPTION QTY ITEM PART 1 13200 Crankcase 1 36 13219 2 13000 Oil Filler Plug Assy 1 36A 07125 4 13201 Crankcase Cover 1 37 13022 5 13202 O Ring for 4 1 38 05168 8 06894 Oil Dipstick 1 39 07755 9 01009 O Ring for 8 1 40 05192 10 13133 Hexagon Screw 12 41 13222 11 06725 Spring Washer 12 41A 07721 12 07109 Drain Plug 3 41B 13223 13 07182 Seal for 12 2 41C 12055 14 12549 Bearing Cover 2 41D 07693 15 13205 Radial Shaft Seal 2 42 07173 16 08055 O Ring for 14 2 43 05176 20 13206 Taper Roller Bearing 2 44 06096 20A 13207 Fitting Disc 1 5 44A 05174 21 13208 Shaft Protector 1 45 13360 22 06895 Crankshaft 1 46 05169 23 08213 Fitting Key 1 49 13159 24 06896 Connecting Rod Assy 3 49A 13160 25 06897 Crosshead Assy 3 49C 13162 28 06898 Crosshead Pin 3 50 05191 30 13214 Cover Plate 1 SIA 12564 30A 07225 0100 Hexagon Screw 4 51B 12565 30B 13136 Grommet 4 51C 12566 30C 07622 Disc 4 51D 12567 31 07623 Eye Bolt 1 52 05166 32 06118 Radial Shaft S
4. carefully onto o rings 41A and 41B of seal case and centering studs 49C 19 Tighten nuts 49A to 103 ft Ibs 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 conn
5. 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 On Pw 0 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 FURTH
6. ER 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 RANTIES OR MERCHANTABILITY OR FITNESS FORA 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 8 07 GP6132 PMD
7. Triplex Ceramic Plunger Pump 0 e Operating Instructions Repair and Service GP6132 u Contents Installation Instructions page 2 Pump Specs page 3 Exploded View page 4 Parts List Kits page 5 Torque Specifications page 5 Repair Instructions page 6 Troubleshooting Chart page 7 Recommended Spare Parts page 7 Dimensions back page Warranty Information back page Updated 8 07 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
8. ck inlet lines for restrictions and or proper size Re size discharge plumbing to flow rate of pump Replace plungers Adjust or Replace packing seals Reduce suction vacuum Replace plungers Reduce inlet pressure Giant oil is recommended Adjust oil level to proper amount Preventative Maintenance Check List amp Recommended Spare Parts List Daily Weekly 50 Hrs Every 500 Hours Every 1500 Hours Every 3000 Hours Oil Level Quality X J OilLeaks X WaterLeaks X Belts Puelly X Plumbing x Recommended Spare Parts GP6132 DIMENSIONS mm 509 621 Druckanschluf 2 x Gt 1 4 Discharge Connection Fitting Key A12x8x63 Centring Hole DR M10 DIN332 Sauganschlu 2 x G2 1 2 Suction Connection 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
9. eal 3 56 05171 32A 13215 Grooved Ring 3 57 05167 33 13216 Seal Retainer 3 59 07661 33A 07721 O Ring for 33 3 60 13151 33B 13217 Circlip for 33 3 61 13171 33C 12551 Fitting Disc not shown 3 66 13362 34 13218 Oil Scraper 3 67 13358 GP6132 REPAIR KITS Plunger Packing Kit 09319 Valve Assembly Kits 09320 Item Part Description Qty Item Part Description Qty 41A 07721 O Ring 3 51A 12564 Valve Seat 6 41B 13223 Support ring 3 518 12565 Valve Plate 6 410 12055 O Ring 6 51C 12566 Valve Spring 6 41D 07693 Support Ring 6 52 05166 O Ring 6 44 06096 Sleeve 6 57 05167 O Ring 3 45 13360 Leakage Seal 3 GP6132 TORQUE SPECIFICATIONS Position lItem Description 10 13133 Inner Hexagon Screw 36 13219 Plunger Connection 38 05168 Tensioning Screw 49A 13160 Nut Valve Casing 56 05171 Tensioning Plug 160 ft lbs 13215 Grooved Ring QTY RRR R LLOOOOO KN CO WW WWD WW WW WW WW WW W Qty 3 3 3 REPAIR INSTRUCTION GP6132 To Check Valves 1 Loosen plugs 56 and take out complete valve assemblies 51 with a slide hammer Use a bent piece of wire to remove the o rings 52 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 i
10. ecting rods have to be able to slightly moved sidewise at the stroke journals 6 REPAIR INSTRUCTION GP6132 PUMP SYSTEM MALFUNCTIONS MALFUNCTION CAUSE The Pressure and or the Delivery Drops Water in Crankcase Noisy Operating Rough Pulsating Operation with Pressure Drop Pump Pressure as Drop at gun Rated Pressure Excessive Leakage High Crankcase Temperature Worn packing seals Broken valve springs Belt slippage Worn or Damaged nozzle Fouled discharge valve Worn or Plugged relief valve on pump Cavitations Unloader High Humidity Worn Seals Worn bearings Cavitation Worn packing Inlet restriction Accumulator pressure Unloader Cavitation Restricted discharge plumbing Worn plungers Worn packing seals Excessive vacuum Cracked plungers Inlet pressure too high Wrong Grade of Oil Improper amount of oil in crankcase REMEDY Replace packing seals Replace springs Tighten or Replace belt Replace nozzle Clean valve assembly Clean Reset and Replace worn parts Check suction lines on inlet of pump for restrictions Check for proper operation Reduce oil change intervals Replace seals Replace bearings Refill crankcase oil with recommended lubricant Check inlet lines for restrictions and or proper sizing Replace packing Check system for stoppage air leaks correctly sized inlet plumbing to pump Recharge Replace accumulator Check for proper operation Che
11. n the valve casing 5 Tighten the plugs 56 to 160 ft Ibs 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
12. 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 connec tions 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 pulsa tion 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 desig nated 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 ob tained 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 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
Download Pdf Manuals
Related Search