Page 1
Model
GP6132
Triplex Ceramic
Plunger Pump
Operating Instructions/
Repair and Service
Manual
Updated 8/07
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
Page 2
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.
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.
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.
A pressure relief
NOTE: Contact Giant Industries for Service School Information. Phone: (419)-531-4600
2
Page 3
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 HORSEPOW ER REQUIREMENTS
RPM GP M 1000 PS I 1500 P S I 2500 P S I 3045 PS I
400 11.8 8.1 12.2 20.3 24. 7
500 14.7 10.1 15.2 25.3 30.8
600 17.6 12.2 18.2 30.4 37.0
700 20.6 14.2 21.3 35.5 43.2
800 23.5 16.2 24.3 40.5 49.4
3
Page 4
EXPLODED VIEW - GP6132
4
Page 5
GP6132 SPARE PARTS LIST
ITEM PART DESCRIPTION QTY.
1 13200 Crankcase 1
2 13000 Oil Filler Plug Assy 1
4 13201 Crankcase Cover 1
5 13202 O-Ring for 4 1
8 06894 Oil Dipstick 1
9 01009 O-Ring for 8 1
10 13133 Hexagon Screw 12
11 06725 Spring Washer 12
12 07109 Drain Plug 3
13 07182 Seal for 12 2
14 12549 Bearing Cover 2
15 13205 Radial Shaft Seal 2
16 08055 O-Ring for 14 2
20 13206 Taper Roller Bearing 2
20A 13207 Fitting Disc 1-5
21 13208 Shaft Protector 1
22 06895 Crankshaft 1
23 08213 Fitting Key 1
24 06896 Connecting Rod Assy 3
25 06897 Crosshead Assy 3
28 06898 Crosshead Pin 3
30 13214 Cover Plate 1
30A 07225-0100 Hexagon Screw 4
30B 13136 Grommet 4
30C 07622 Disc 4
31 07623 Eye Bolt 1
32 06118 Radial Shaft Seal 3
32A 13215 Grooved Ring 3
33 13216 Seal Retainer 3
33A 07721 O-Ring for 33 3
33B 13217 Circlip for 33 3
33C 12551 Fitting Disc (not shown) 3
34 13218 Oil Scraper 3
ITEM PART DESCRIPTION QTY.
36 13219 Plunger Connection 3
36A 07125 Centering Sleeve 3
37 13022 Plunger Pipe 3
38 05168 Tensioning Screw 3
39 07755 Copper Ring 3
40 05192 Seal Sleeve 3
41 13222 Seal Case 3
41A 07721 O-Ring for 41 3
41B 13223 Support Ring for 41A 3
41C 12055 O-Ring for 41 3
41D 07693 Support Ring for 41C 3
42 07173 Tension Spring 3
43 05176 Sleeve Support Ring 3
44 06096 Sleeve 6
44A 05174 Pressure Ring 3
45 13360 Leakage Seal 3
46 05169 Threaded Pipe 3
49 13159 Stud Bolt 8
49A 13160 Nut 8
49C 13162 Centring Stud 2
50 05191 Valve Casing 1
51A 12564 Valve Seat 6
51B 12565 Valve Plate 6
51C 12566 Valve Spring 6
51D 12567 Spacer Pipe 6
52 05166 O-Ring for 51 6
56 05171 Plug 3
57 05167 O-Ring for 56 3
59 07661 Copper Seal for 12 1
60 13151 Plug, 1-1/4” BSP 1
61 13171 Plug, 2-1/2” BSP 1
66 13362 Disc for Cr anksh aft 1
67 13358 Hexagon Screw 1
Plunger Packing Kit # 09319
Item Part # Description Qty.
41A 07721 O-Ring 3
41B 13223 Support ring 3
41C 12055 O-Ring 6
41D 07693 Support Ring 6
44 06096 Sleeve 6
45 13360 Leakage Seal 3
GP6132 TORQUE SPECIFICATIONS
Position Item# Description Torque Amount
10 13133 Inner Hexagon Screw 30 ft.-lbs.
36 13219 Plunger Connection 33 ft.-lbs.
38 05168 Tensioning Screw 30 ft.-lbs.
49A 13160 Nut, Valve Casing 103 ft.-lbs.
56 05171 Tensioning Plug 160 ft.-lbs.
GP6132 REPAIR KITS
Valve Assembly Kits #09320
Item Part # Description Qty.
51A 12564 Valve Seat 6
51B 12565 Valve Plate 6
51C 12566 Valve Spring 6
52 05166 O-Ring 6
57 05167 O-Ring 3
5
Oil Seal Kit # 09304
Item Part # Description Qty.
32 06118 Radial Shaft Seal 3
32A 13215 Grooved Ring 3
33A 07721 O-Ring 3
Page 6
REPAIR INSTRUCTION - GP6132
To Check V alves
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 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 V alve 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
Page 7
REPAIR INSTRUCTION - GP6132
y
g
y
y Op
g
p
p
g
Adj
p
PUMP SYSTEM MALFUNCTIONS
MALFUNCTION CAUSE REMEDY
The Pressure and/
or the Deliver
Drops
Worn packing seals R eplace packing seals
Broken valve springs Replace springs
Belt slippage Tighten or Replace belt
Worn or Damaged nozzle Replace noz zle
Fouled discharge valve 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 restricti ons
Unloader Check for proper operation
Water in Crankcase Hi
Nois
eratin
crankcase oil with recommended
and/or proper sizing
Rough/Pulsating
Operation with
Pressure Dro
Pump Pressure as
Drop at gun Rated,
Pressure
Excessive
Leaka
e
High Crankcase
erature
Tem
h Humidit
Worn Seals Replace seals
Worn bearingsRe
Cavitation Check inlet lines for restrictions
Worn packing Replace packing
Inlet restriction Check system for stoppage
Accumulator pressure Recharge/Replace accumulato r
Unloader Check for proper operation
Cavitation Check inlet lines for restrictions
Restricted discharge plum bing Re-size discharge plumbing to flow
Worn plungers Replace plungers
Worn packing/seals
Excessive vacuum Reduce suction vacuum
Cracked plungers Replace plungers
Inlet pressure too high Reduce inlet pressure
Wrong Grade of Oil Giant oil is recommended
Improper amount of oil in crankcase Adjust oil level to proper amount
Reduce oil change intervals
lace bearings, Refill
lubricant
air leaks, correctly sized
inlet plumbing to pump
and/or proper size
rate of pump
ust or Replace packing seals
Preventativ e Maintenance Check List & Recommended Spare Parts List
Every
3000
Hours
Check Daily Weekly 50 Hrs.
Every
500
Hours
Every
1500
Hours
Oil Level/Quality X
Oil Leaks X
Water Leaks X
Belts, Puelly X
Plumbing X
Recommended Spare Parts
Oil Change
(1 gallon) p/n 01154
XX
Plunger Seal Kit
(1 kit/pump)
X
Oil Seal Kit
(1 kit/pump)
X
Valve Repair Kit
(1 kit/pump)
X
7
Page 8
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.
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
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 under
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
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