Giant GP5132 User Manual

Triplex Ceramic
Plunger Pump
Operating Instructions/
Manual

Models
GP5132, GP5136 & GP5145

Contents:

Installation Instructions: page 2
Pump Specifications: pages 3-5
Parts List/Exploded View: pages 6-7
Kits/Torque Specs: page 8
Trouble Shooting: page 9
Repair Instructions: page 10-11
Dimensions: back page
Warranty Informationback 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 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 spikes in the event of a blockage or the use of
a shut-off gun.

0

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 3-5.

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.

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.

IMPORTANT OPERATING CONDITIONS
Failure to comply with any of these condi-

tions invalidates the warranty

1. Prior to initial operation, add oil to crankcase so that oil
level is between the two lines on the oil dipstick. DO NOT
OVERFILL. SAE 80 or SAE 90 Industrial Gear oil may
be used. 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.

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.

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: [phone]

2

Specifications

Volume ................................................................................................... Up to 29 GPM

Model GP5132

Discharge Pressure ................................................................................ Up to 3000 PSI

Speed ..................................................................................................... Up to 1000 RPM

Inlet Pressure ......................................................................................... Up to 145 PSI

Plunger Diameter .................................................................................... 32 mm

Plunger Stroke ........................................................................................ 46mm

Crankshaft Diameter .............................................................................. 35mm x 10mm key

Crankshaft Mounting .............................................................................. Either side

Shaft Rotation.............................................................................Top of pulley towards manifold

Temperature of Pumped Fluids ............................................................... Up to 140 oF

Inlet Ports............................................................................................... (3) 1-1/2" BSP

Discharge Ports ...................................................................................... (2) 1" BSP

Weight .................................................................................................... 179 lbs.

Crankcase Oil Capacity .......................................................................... 1.2 Gal.

Fluid End Material................................................................................... Cast Iron

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.

GP5132 HORSEPOWER

REQUIREMENTS

RPM GPM

600 17.4 12 18 24 30 36

700 20.3 14 21 28 35 42

900 26.1 18 27 36 45 54

1000 29 20 30 40 50 60

1OOO

SPECIAL NOTE:

PSI

15OO

PSI

2OOO

PSI

25OO

PSI

3000

PSI

FOR CONTINUAL OPERATION, THE SPEED

OF THE PUMP MUST BE LIMITED TO 700

RPM, AND THE MAXIMUM PRESSURE OF THE

PUMP MUST BE REDUCED BY 10%.

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

3

Specifications

Volume ................................................................................................... Up to 35 GPM

Model GP5136

Discharge Pressure ................................................................................ Up to 2200 PSI

Speed ..................................................................................................... Up to 945 RPM

Inlet Pressure ......................................................................................... Up to 145 PSI

Plunger Diameter .................................................................................... 36mm

Plunger Stroke ........................................................................................ 46mm

Crankshaft Diameter .............................................................................. 35mm x 10mm key

Crankshaft Mounting .............................................................................. Either side

Shaft Rotation.............................................................................Top of pulley towards manifold

Temperature of Pumped Fluids ............................................................... Up to 140 oF

Inlet Ports............................................................................................... (3) 1-1/2" BSP

Discharge Ports ...................................................................................... (2) 1" BSP

Weight .................................................................................................... 179 lbs.

Crankcase Oil Capacity .......................................................................... 1.2 Gal.

Fluid End Material................................................................................... Cast Iron

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.

GP5136 HORSEPOWER

REQUIREMENTS

RPM GPM

700 26 18 27 33 36.3 39.4

750 28 19 29 35 39 42.5

800 30 21 31 37 41 45.5

850 32 22 33 40 44 48.6

945 35 24.1 36.2 43.4 48.2 53.1

1OOO

SPECIAL NOTE:

PSI

15OO

PSI

1800

PSI

2000

PSI

2200

PSI

FOR CONTINUAL OPERATION, THE SPEED

OF THE PUMP MUST BE LIMITED TO 700

RPM, AND THE MAXIMUM PRESSURE OF THE

PUMP MUST BE REDUCED BY 10%.

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

4

Specifications

Volume ................................................................................................... Up to 43.3 GPM

Model GP5145

Discharge Pressure ................................................................................ Up to 1500 PSI

Speed ..................................................................................................... Up to 750 RPM

Inlet Pressure ......................................................................................... Up to 145 PSI

Plunger Diameter .................................................................................... 45mm

Plunger Stroke ........................................................................................ 46mm

Crankshaft Diameter .............................................................................. 35mm x 10mm key

Crankshaft Mounting .............................................................................. Either side

Shaft Rotation.............................................................................Top of pulley towards manifold

Temperature of Pumped Fluids ............................................................... Up to 140 oF

Inlet Ports............................................................................................... (3) 1-1/2" BSP

Discharge Ports ...................................................................................... (2) 1" BSP

Weight .................................................................................................... 179 lbs.

Crankcase Oil Capacity .......................................................................... 1.2 Gal.

Fluid End Material................................................................................... Cast Iron

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.

GP5145 HORSEPOWER

REQUIREMENTS

RPM GPM

550 31.9 22 24.2 28.6 33

600 34.9 24.1 26.5 31.3 36.1

650 37.8 26 28.7 33.9 39.1

700 40.6 28 30.8 36.4 42

750 43.3 29.9 32.8 38.8 44.8

1OOO

PSI

SPECIAL NOTE:

1100

PSI

1300

PSI

1500

PSI

FOR CONTINUAL OPERATION, THE SPEED

OF THE PUMP MUST BE LIMITED TO 700

RPM, AND THE MAXIMUM PRESSURE OF THE

PUMP MUST BE REDUCED BY 10%.

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

5

GP5100 Series PARTS LIST

ITEM PART DESCRIPTION QTY.

1 13266 Crankcase 1
2 13000 Oil Filler Plug Assembly 1
3 07186 Oil Sight Glass Assy. 1
4 13267 Crankcase Cover 1
5 13268 O-Ring 1
8 07105 Oil Dip Stick 1
9 01009 O-Ring, Dip Stick 1
10 13270 Inner Hexagon Screw 4
11 13134 Spring Washer 4
12 07703 Drain Plug G 3/4" 1
13 13269 Gasket, Drain Plug 1
14 13271 Bearing Cover 2
15 13272 Radial Shaft Seal 2
16 08182 O-Ring 2
17 13358 Hexagon Screw 8
18 13134 Spring Washer 8
20 13206 Taper Roller Bearing 2
20A 13207 Fitting Disc (Shim) 5
21 13273 Shaft Protector 1
22 13274 Crankshaft 1
23 13275 Fitting Key 1
24 13276 Connecting Rod Assy. 3
25 13279 Crosshead Assy. 3
28 13281 Crosshead Pin 3
29A 07125 Centering Sleeve 3
29B 13022 Plunger Pipe (GP5132) 3
29B 07130 Plunger Pipe (GP5136) 3
29B 13283 Plunger Pipe (GP5145) 3
29C 07131 Tension Screw 3
29D 07755 Oil Scraper 3
30 13282 Copper Ring 3
31 13284 Radial Shaft Seal 3
35 13359 Seal Sleeve (GP5132) 3
35 13288 Seal Sleeve (GP5136) 3
35 13287 Seal Sleeve (GP5145) 3
35A 13289 O-Ring (GP5136) 3
35A 13286 O-Ring (GP5145) 3
35B 08183 O-Ring 3
36 13360 Grooved Ring (GP5132) 3
36 13291 Grooved Ring (GP5136) 3
36 13290 Grooved Ring (GP5145) 3
37 13361 Seal Case (GP5132) 3
37A 07700 O-Ring (GP5132) 3

ITEM PART DESCRIPTION QTY.

37B 07653 O-Ring (GP5132) 3
39 13026 Pressure Ring (GP5132) 3
39 07142 Pressure Ring (GP5136) 3
39 13293 Pressure Ring (GP5145) 3
40 13027 V-Sleeve (GP5132) 6
40 07144 V-Sleeve (GP5136) 6
40 13294 V-Sleeve (GP5145) 6
41 13028 Sleeve Support Ring

(GP5132) 3

41 07146 Sleeve Support Ring

(GP5136) 3

41 13296 Sleeve Support Ring

(GP5145) 3
42 07173 Tension Spring (GP5132) 3
42 07147 Tension Spring (GP5136) 3
42 13297 Tension Spring (GP5145) 3
42A 13298 Spring Guide (GP5136 only) 3
43 13300 Valve Casing 1
46 13302 Suction Valve Assy. 3
46A 12055 O-Ring 1*
46B 08059 O-Ring 1*
46C 13304 Suction Valve Seat 1*
46D 13306 Valve Plate 1*
46E 13307 Valve Spring 1*
46F 13308 Spring Tension Cap 1*
46G 13309 Spacer Pipe 1*
47 13311 Discharge Valve Assy. 3
47A 13312 O-Ring 1*
47B 07700 O-Ring 1*
47C 13314 Discharge Valve Seat 1*
47D 13306 Valve Plate 1*
47E 13307 Valve Spring 1*
47F 13308 Spring Tension Cap 1*
48 13316 Plug 3
48A 07008 Inner Hexagon Screw 12
48B 07740 O-Ring 3
48C 07232 Pressure Ring 3
49 13362 Inner Hexagon Screw 8
52 13363 Disc for Crankshaft 1
53 13358 Hexagon Screw 1
54 13321 Plug G 1" 1
55 13322 Plug G 1-1/2" 2

6

Exploded View - GP5100 Series

7

GP5100 SERIES REPAIR KITS

Plunger Packing Kits

GP5132 #09290

Qty. Part # Description
3 08183 O-Ring
3 13360 Grooved Ring
6 13027 V-Sleeve

GP5136 #09229

Qty. Part # Description
3 13289 O-Ring
3 08183 O-Ring
3 13291 Grooved Ring
6 07144 V-Sleeve

GP5145 #09228

Qty. Part # Description
3 13286 O-Ring
3 08183 O-Ring
3 13290 Grooved Ring
6 13294 V-Sleeve

Valve Assembly Kits

Inlet Valve Kit, GP5100 Series, #09231

Qty. Part # Description
1 12055 O-Ring
1 08059 O-Ring
1 13304 Valve Seat
1 13306 Valve Plate
1 13307 Valve Spring

Discharge Valve Kit, GP5100 Series, # 09232

Qty. Part # Description
1 13312 O-Ring
1 07700 O-Ring
1 13314 Valve Seat
1 13306 Valve Plate
1 13307 Valve Spring

Oil Seal Kit

GP5100 Series, #09230

Qty. Part # Description
3 13284 Oil Seal

GP5100 SERIES TORQUE SPECIFICATIONS

Position Item# Description Torque Amount (ft.-lbs)

24 13276 Connecting Rod Assy. 26

29C 07131 Tension Screw, Plunger 26

48A 07008 Inner Hexagon Screw, Plug 35

49 13362 Inner Hexagon Screw, Valve Casing 85

8

PUMP SYSTEM MALFUNCTION

MALFUNCTION CAUSE REMEDY

The Pressure and/ Worn packing seals Replace packing seals
or the Delivery Broken valve spring Replace spring
Drops Belt slippage Tighten or Replace belt

Worn or Damaged nozzle Replace nozzle
Fouled discharge valve Clean valve assembly
Fouled inlet strainer Clean strainer
Worn or Damaged hose Repair/Replace hose
Worn or Plugged relief valve on pump Clean, Reset, and Replace worn parts
Cavitation Check suction lines on inlet of
pump for restrictions
Unloader Check for proper operation

Water in crankcase High humidity Reduce oil change interval

Worn seals Replace seals

Noisy Operation Worn bearings Replace bearings, Refill crankcase

oil with recommended lubricant

Cavitation Check inlet lines for restrictions

and/or proper sizing

Rough/Pulsating Worn packing Replace packing
Operation with Inlet restriction Check system for stoppage, air
Pressure Drop leaks, correctly sized inlet

plumbing to pump
Accumulator pressure Recharge/Replace accumulator
Unloader Check for proper operation
Cavitation Check inlet lines for restrictions
and/or proper size

Pump Pressure as Restricted discharge plumbing Re-size discharge plumbing to Drop
at gun flow rate of pump
Rated, Pressure

Excessive Worn plungers Replace plungers
Leakage Worn packing/seals Adjust or Replace packing seals

Excessive vacuum Reduce suction vacuum
Cracked plungers Replace plungers
Inlet pressure too high Reduce inlet pressure

High Crankcase Wrong Grade of oil Giant oil is recommended
Temperature Improper amount of oil in crankcase Adjust oil level to proper amount

9

REPAIR INSTRUCTIONS

Note: Always take time to lubricate all metal and nonmetal parts with a light film of oil before

reassembly. This step will ensure proper fit, at the same time protecting the pump's non­metal parts (i.e., the elastomers) from cutting and scoring.

To Check Valves

1. Screw-out inner hexagon screws (48A) with an allen wrench. Remove discharge plugs (48) with a screw driver.
Check O-Rings (48B) on discharge plugs and replace as necessary.

2. Pull out Pressure Ring (48C). Remove the Spring Tension Cap (47F) from the discharge Valve Plate (47D)
lying underneath by screwing in the 10mm screw. Take out the Valve Spring (47E) and Valve Plate (47D). Pull
out the Discharge Valve Seat (47C) by means of slide hammer. Check sealing areas of the Valve Plate (47D)
and the Valve Seat (47C) for damage and replace worn parts. Check O-Rings (47A and 47B) and replace as
necessary.

3. Screw Spacer Pipe (46G) out of the Spring Tension Cap (46F) located in the suction valve lying underneath.
Remove the Suction Valve Assembly (46) by screwing in a 10mm screw. Check O-Rings (46A and 46B) and
replace as necessary. If the Suction Valve Seat (46C) remains in the Valve Casing (43), remove it with a slide
hammer. Check the sealing areas of the Suction Valve Plate (46D) and the Suction Valve Seat (46C) for
damage and replace worn parts.

4. After reassembling the above items, tighten the Inner Hexagon Screws (48A) to 35 ft.-lbs.

To Check Seals and Plunger Pipes

1. Loosen the eight Inner Hexagon Screws (49) and pull of the Valve Casing (43) to the front. Pull Seal Sleeves
(35) out of the guides in the crankcase and over the plunger pipes (29B). Remove Sleeve Support Ring (41),
Sleeves (40) and Grooved Rings (36). Replace worn parts as necessary.

2. If a Plunger Pipe (29B) is worn out, loosen the Tension Screw (29C) and pull off the Plunger Pipe to the front.
Clean the contact surfaces of the Crosshead Assembly (25) thoroughly. Place the new plunger pipe carefully
through oiled seals back into the seal case. Check O-Rings (35A and 35B) on the Seal Sleeves (35) and
replace as necessary.

3. Push the Seal Sleeves (35) together with the Plunger Pipe (29B) back into the crankcase guide. Turn the
crankshaft (22) carefully until the Crosshead Assembly (25) comes up against the Plunger Pipe. Put a new Oil
Scraper (29D) onto the Tension Screw (29C). Cover the thread of the Tension Screw and the Oil Scraper and
apply a liquid adhesive such as Lock-Tite. Tighten Tension Screw to 26 ft.-lbs..

Important!!

Do not get any adhesive between the Plunger Pipe (29B) and the Centering Sleeve (29A). The
Plunger Pipe should not be strained by excessive force on the Tension Screw (29C) or through dam­age to the front surface of the Plunger. If these conditions are ignored, the Plunger Pipe will prob­ably break.

4. Tighten the Inner Hexagon Screws (49) to the Valve Casing (43) to 85 ft.-lbs.

10

To Disassemble Gear End

1. Loosen Inner Hexagon Screws (49) for the Valve Casing (43) with an allen wrench. Carefully remove Valve
Casing from the Crankcase (1).

2. Loosen Inner Hexagon Screws (10) for the Crankcase Cover (4) with an allen wrench and remove Crankcase
Cover.

3. Loosen Hexagon Screws (17) for the Bearing Covers (14) with a wrench and remove Bearing Cover.

4. Drain oil from the Crankcase (1) by removing Drain Plug (12) with a 3/4" wrench.

5. Loosen Connecting Rod Screws (24) with an allen wrench. Push the stems of the connecting rods as far as
possible into the crosshead guides. Carefully push out the Radial Shaft Seals(31).

Important!!
Connecting Rods (24) are marked for identification. Do not twist Connecting Rod halves. Connect­ing Rods must be reinstalled in the same position on the Crankshaft (22) journals.

6. While slightly turning the Crankshaft (22), hit it out carefully to one side with a rubber hammer.

Important!!
Do not bend Connecting Rod (24) shank.

7. Check the surfaces of the Crankshaft (22), Connecting Rods (24), Crosshead Assemblies (25) as well as the
Radial Shaft Seals (15 and 31) and Taper Roller Bearings (20).

To Reassemble Gear End

1. Using a soft tool, such as brass or wooden dowel, press in the outer bearing ring until it lines up with the outer
edge of the bearing hole. Assemble the Bearing Cover (14) together with the Shaft Seal (15) and O-Ring (16).

2. Fit the Crankshaft (22) with pressed-on bearing parts through the bearing hole on the opposite side. Press in
outer bearing ring and push it inwards with the Bearing Cover (14) while keeping the Crankshaft in the vertical
position and turning it slowly so that the taper rollers of the bearings touch the edge of the outer bearing ring.

3. Adjust axial bearing clearance with Fitting Discs (20A) which are 0.1mm each. The Crankshaft (22) should turn
easily with very little clearance. Tighten Inner Hexagon Screws on the Connecting Rods (24) to 26 ft.-lbs..

Important!!
There should be enough clearance for the Connecting Rods (24) to move sideways a little on the
journals.

11

DIMENSIONS

10mm X 63mm Key

OUTLET

18.9"

4.61" 13.9"

3.06"

9.06"

4.33"

2.17"

7.68"

INLET

20.6"

9.69"

8.27"

10.2"

19.1"

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.

2.68"

2.87"

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 [phone] 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 [phone], FAX [phone], www.giantpumps.com
 Copyright 1996 Giant Industries, Inc.

3/98 GP5100.PM6