Triplex Ceramic
Plunger Pump
Operating Instructions/
Manual
Model
GP6124 & GP6128
Updated 3/98
Contents:
Installation Instructions: page 2
Pump Specs.(GP6124): page 3
Exploded View: page 4
Parts List / Kits: page 5
Pump Specs.(GP6128): page 6
Repair Instructions: page 7
Torque Specifications: page 7
Dimensions: back page
Warranty Information: 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
0
F, it is important to insure a positive head
140
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
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
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.
2. Pump operation must not exceed rated
pressure, volume, or RPM.
A pressure relief
device must be installed in the discharge of the
system.
SAE 80 Industrial Gear oil may be used.
3. Acids, alkalines, or abrasive fluids cannot be
Crankcase oil should be changed after the
first 50 hours of operation, then at regular
pumped unless approval in writing is obtained
before operation from Giant Industries, Inc.
intervals of 500 hours or less depending on
operating conditions.
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
Volume ........................................................................................................ Up to 12.8 GPM
Model GP6124
Discharge Pressure .................................................................................... Up to 5800 PSI
Speed .......................................................................................................... Up to 800 RPM
Inlet Pressure .............................................................................................. Up to 90 PSI
Plunger Diameter ........................................................................................ 24mm
Plunger Stroke ............................................................................................ 48mm
Crankshaft Diameter .................................................................................. 42mm
Key Width ................................................................................................... 12mm
Crankshaft Mounting .................................................................................. Either side
Shaft Rotation ................................................................................ Top of pulley towards manifold
Temperature of Pumped Fluids ................................................................... Up to 140
Inlet Ports ................................................................................................... (2) 1 1/2" NPT
Discharge Ports .......................................................................................... (2) 1" NPT
Weight......................................................................................................... 309 lbs.
Crankcase Oil Capacity .............................................................................. 1.9 Gal.
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.
1
o
F
NOTES: 1 Positive inlet pressures are recommended!
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
GP6124 HORSEPOWER REQUIRMENTS
RPM GPM 1000 PSI 2500 PSI 4000 PS I 5800 P SI
400 6.4 4. 6 11.4 18.3 26.5
500 8.0 5. 7 14.3 22.9 33.2
600 9.6 6. 9 17.2 27.5 39.8
700 11.2 8.0 20.0 32.0 46.4
800 12.8 9.2 22.9 36.6 53.1
3
Exploded View - GP6124 & GP6128
4
GP6124 & GP6128 PARTS LIST
ITEM PART DESCRIPTION QTY.
1 13200 Crankcase 1
2 13000 Oil Filler Plug Assembly 1
4 13201 Crankcase Cover 1
5 13202 O-Ring, Crankcase Cover 1
8 13203 Oil Dip Stick 1
9 01009 O-Ring, Dip Stick 1
10 13133 Hexagon Screw 12
11 13134 Spring Washer 12
12 07109 Drain Plug 5
13 07182 Gasket, Drain Plug 2
14 13204 Bearing Cover 2
15 13205 Radial Shaft Seal 2
16 08055 O-Ring 2
20 13206 Taper Roller Bearing 2
20A 13207 Fitting Disc (Shim) 1-5
21 13208 Shaft Protector 1
22 13209 Crankshaft 1
23 08213 Key 1
24 13211 Connecting Rod Assy. 3
25 13212 Crosshead Assy. 3
28 13213 Crosshead Pin 3
30 13214 Cover Plate 1
30 A 07225-0100 Hexagon Screw 4
30B 13136 Grommet 4
30C 07622 Washer 4
31 07623 Eye Bolt 1
32 06118 Radial Shaft Seal 3
32A 13215 Grooved Ring 3
33 13216 Seal Retainer 3
33 A 07721 O-Ring 3
33B 13217 Circlip 3
34 13218 Flinger 3
36 13219 Plunger Connection (GP6128) 3
36 A 07125 Centering Sleeve (GP6128) 3
37 13397 Plunger Pipe (GP6124) 3
37 13220 Plunger Pipe (GP6128) 3
38 07131 Tensioning Screw (GP6128) 3
39 07755 Copper Ring (GP6128) 3
ITEM PART DESCRIPTION QTY.
40 13398 Seal Sleeve (GP6124) 3
40 13221 Seal Sleeve (GP6128) 3
41 13399 Seal Case (GP6124) 3
41 13222 Seal Case (GP6128) 3
41A 12055 O-Ring (GP6124) 6
41A 07721 O-Ring (GP6128) 3
41B 07693 Support Ring (GP6124) 6
41B 13223 Support Ring (GP6128) 3
41C 12055 O-Ring (GP6128) 3
41D 07693 Support Ring (GP6128) 3
42 13400 Grooved Ring (GP6124) 3
42 07173 Tension Spring (GP6128) 3
43 07685 Packing (GP6124) 3
43 13368 Support Ring (GP6128) 3
43A 07718 Support Ring (GP6124) 6
44 13401 Guide Ring (GP6124) 3
44 13369 V-Sleeve (GP6128) 6
44A 13370 Pressure Ring (GP6128) 3
45 13238 Leakage Seal (GP6124) 3
45 13228 Leakage Seal (GP6128) 3
46 07644 Threaded Pipe 3
49 13159 Stud Bolt 8
49A 13160 Nut 8
49C 13162 Centering Stud 2
50 13229 Valve Casing 1
51 A 07064 Valve Seat 6
51B 13130 Valve Plate (GP6124) 6
51B 07063 Valve Plate (GP6128) 6
51C 07062 Valve Spring 6
51D 07066 Spacer Pipe 6
56 06077 Tensioning Plug 3
56 A 07150 O-Ring 12
56B 06266 Support Ring 3
56C 06078 Spring 3
57 13230 Spacer Ring 3
59 07661 Copper Ring 3
60 13044 Plug 1
61 13045 Plug 1
66 13362 Disc, Crankshaft 1
67 13358 Inner Hexagon Screw 1
Plunger Packing Kits
GP 6124 # 09311
Qty. Part # Description
3 07721 O-Ring
6 07693 Support Ring
6 12055 O-Ring
3 07685 Packing
3 13400 Grooved Ring
3 13238 Leakage Seal
6 07718 Support Ring
GP 6128 # 09302
Qty. Part # Description
3 07721 O-Ring
3 13223 Support Ring
3 12055 O-Ring
3 07693 Support Ring
6 13369 V-Sleeve
3 13228 Leakage Seal
GP6124 & GP6128 REPAIR KITS
Valve Assembly Kits
GP6124 # 09312
Qty. Part # Description
6 07064 Valve Seat
6 13130 Valve Plate
6 07062 Valve Spring
12 07150 O-Ring
3 06266 Support Ring
GP6128 # 09303
Qty. Part # Description
6 07064 Valve Seat
6 07063 Valve Plate
6 07062 Valve Spring
12 07150 O-Ring
3 06266 Support Ring
5
Oil Seal Kit
# 09304
Qty. Part # Description
3 06118 Radial Shaft Seal
3 13215 Grooved Ring
3 07721 O-Ring
Specifications
Volume ........................................................................................................ Up to 18.0 GPM
Model GP6128
Discharge Pressure .................................................................................... Up to 4000 PSI
Speed .......................................................................................................... Up to 800 RPM
Inlet Pressure .............................................................................................. Up to 90 PSI
Plunger Diameter ........................................................................................ 28mm
Plunger Stroke ............................................................................................ 48mm
Crankshaft Diameter .................................................................................. 42mm
Key Width ................................................................................................... 12mm
Crankshaft Mounting .................................................................................. Either side
Shaft Rotation ................................................................................ Top of pulley towards manifold
Temperature of Pumped Fluids ................................................................... Up to 140
Inlet Ports ................................................................................................... (2) 1 1/2" NPT
Discharge Ports .......................................................................................... (2) 1" NPT
Weight......................................................................................................... 309 lbs.
Crankcase Oil Capacity .............................................................................. 1.9 Gal.
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.
1
o
F
NOTES: 1 Positive inlet pressures are recommended!
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
GP6128 HORSEPOWER REQUIRMENTS
RPM GPM 1000 PSI 2000 PS I 3000 PSI 4000 PSI
400 18. 0 6.2 12.4 18.6 24.8
500 15. 8 7.8 15.6 24.2 31.1
600 13. 5 9.3 18.6 27.9 37.2
700 11. 3 10.9 21.8 32.7 43.5
800 9.0 12.4 24. 9 37.2 49.6
6
REPAIR INSTRUCTION - GP6124 & GP6128
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 (56A) 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), guide ring/vsleeve (44) and seals (42, 43, 45). Check o-rings (41A and 41C) and support rings (41B and 41D). 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 for GP6128) or plunger (37 for GP6124) could hit
against the spacer pipe (51D) when the pump is being turned.
For the GP6128, the seal unit (43, 44, 44A) is loaded by 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, 32A, 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.
IMPORTANT:Seal (32A) must always be installed so that the seal lip on the inside diameter faces
the oil.
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 (10)
to 355 in.-lbs.
IMPORTANT: Connecting rod has to be able to be slightly moved sidewise at the stroke journals.
GP6124 & GP6128 TORQUE SPECIFICATIONS
Position Item# Description Torque Amount
10 13133 Inner Hexagon Screw 355 in.-lbs.
36 13219 Plunger Connection 33 ft.-lbs.
38 07131 Tensioning Screw 355 in.-lbs.
49 A 13160 Nut, Valve Casing 103 ft.-lbs.
56 13371 Tensioning Plug 160 ft.-lbs.
7
GP6124 & GP6128 DIMENSIONS
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 NONSALINE, 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
manufacturers 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
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.
prior to the return to Giant Industries of all products
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
Ó Copyright 1997 Giant Industries, Inc.
3/98 GP6124_8.PM6
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