Triplex Ceramic
Plunger Pump
Operating Instructions/
Models
Repair and Service
Manual
MP4130-3100 & MP4135-3100
Updated 07/12
Contents:
Installation Instructions: page 2
Pump Specications: page 3
Exploded View: page 4
Parts List / Kits: page 5
Repair Instructions: page 6-10
Torque Specications: page 10
Pump Mounting Selection Guide: page 10
Troubleshooting/Recommended
Spare Parts List: page 11
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 at 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
ow rate of the pump with no unnecessary re-
strictions that can cause cavitation. Teon tape
should be used to seal all joints. Maximum inlet
o
uid temperature is 160
F (71o C).
3. The discharge plumbing from the pump
should be properly sized to the ow rate to pre-
vent 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 page 3.
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 ow 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.
Use SAE 80W-90 Industrial Gear Lube
Oil (Giant’s p/n 01154)
3. Acids, alkalines, or abrasive uids cannot be pumped unless approval in writing is
Crankcase oil should be changed after
the rst 50 hours of operation, then at regular
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.
2
MP4130-3100 & MP4135-3100
RPM GPM 500 PSI 1000 PSI 1300 PSI 1600 PSI
700 9.8 3.4 6.8 8.8 10.8
800 11.2 3.9 7.7 10.0 12.4
900 12.6 4.3 8.7 11.3 13.9
1000 14.0 4.8 9.7 12.6 15.4
1100 15.4 5.3 10.6 13.8 17.0
MP4130-3100 Horsepower Requirements
RPM GPM 500 PSI 1000 PSI 1300 PSI 1600 PSI
700 11.4 3.9 7.9 10.2 12.6
800 13.0 4.5 9.0 11.7 14.4
900 14.6 5.1 10.1 13.1 16.2
1000 16.3 5.6 11.2 14.6 18.0
1100 17.9 6.2 12.3 16.0 19.8
MP4135-3100 Horsepower Requirements
Pump Specications
U.S. Metric
Volume (MP4130-3100).........................................15.4 GPM .........................................58.2 L/min
Volume (MP4135-3100).........................................17.9 GPM .........................................67.7 L/min
Discharge Pressure ................................................1600 PSI ................................................ 110 Bar
Inlet Pressure ........................................................90 PSI ................................................... 6.2 Bar
Speed ..................................................................................................................... Up to 1100 RPM
Plunger Diameter...................................................1.2” ...........................................................30mm
Plunger Stroke (MP4130-3100) .............................1.0” ...........................................................26mm
Plunger Stroke (MP4135-3100) .............................1.8” ...........................................................30mm
Crankcase Oil Capacity .........................................33.8 .oz. ................................................1 Liter
Temperature of Pumped Fluids .............................Up to 158o F ............................................. 70o C
Inlet Ports .........................................................................................................................(2) 1” NPT
Discharge Ports .............................................................................................................(2) 3/4” NPT
Pulley Mounting ................................................................................................................Either side
Shaft Rotation .................................................................................Top of Pulley Towards Fluid End
Weight ...................................................................66 lbs. .....................................................30 Kg
Crankshaft Diameter..............................................1.1” ...........................................................28mm
Consult the factory for special requirements that must be met if the pump is
to operate beyond one or more of the limits specied above.
PULLEY INFORMATION
Pulley selection and pump speed are based on
a 1725 PRM motor and “B” section belts. When
selecting desired GPM, allow for a ±5% tolerance
on pumps output due to variations in pulleys, belts
and motors among manufacturers.
1. Select GPM required, then select appropriate
motor pulley from the same line.
2. The desired pressure is acheived by selecting
the correct nozzle size that corresponds with the
pump GPM.
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 specied
when selecting an electric motor as the power
source. To compute specic pump horsepower
requirements, use the following formula:
HP = (GPM X PSI) / 1450
3
MP4130-3100 & MP4135-3100 Exploded View
4
MP4130-3100 & MP4135-3100 Spare Parts List
ITEM PART # DESCRIPTION QTY.
1 06100 Crankcase 1
2 13000 Oil Filler Cap Assy 1
4 07243 Cover, Crankcase 1
5 07244 O-Ring, Crankcase Cover 1
8 01008 Oil Dip Stick 1
9 01009 O-Ring, Dip Stick 1
10 01010 Hexagon Socket Screw 4
11 08094 Spring Washer 12
12 12137 Oil Drain Plug 1
13 07182 Gasket, Oil Drain Plug 1
14 07245 Bearing Cover 2
15 07247 Seal, Crankshaft 2
16 07627 O-Ring 2
17 08095 Hex Screw, Bearing Cover 9
20 07248 Roller Bearing, Tapered 2
20A 07249 Shim 1-3
20B 06962 Fitting Disc 2
21 05375 Shaft Protector 1
22 07251 Crankshaft (MP4130-3100) 1
22 04149 Crankshaft (MP4135-3100) 1
23 13331 Key 1
24 07253 Connecting Rod Assembly 3
24A 05349 Hex Screw with Washer 6
25 07254 Crosshead Assembly 3
28 07255 Crosshead Pin 3
29A 07256 Centering Sleeve 3
29B 07261 Plunger Pipe 3
29C 04150 Tension Screw 3
29D 07161-0100 Steel Ring 3
29E 04151 Plunger Extension 3
ITEM PART # DESCRIPTION QTY.
30 06136 Flinger 3
31 07260 Crankcase Oil Seal 3
36 07267-0100 Snap Ring 3
39 07271 Pressure Ring 6
40 07272 V-Sleeve 9
41 07273 Support Ring 6
42 07353 Tension Spring 3
42A 06103 Tension Plug 3
42B 06736 O-Ring, Tension Plug 3
43 04152 Valve Casing 1
44 07280-0100 Valve Seat 6
44A 06003-0001 O-Ring, Valve Seat 6
45 07282 Valve Plate 6
46 07283 Valve Spring 6
47 04153 Spring Tension Cap 3
48 06964 Plug 3
48A 06965 O-Ring, Plug 3
49 06139 Stud Bolt 6
49A 06140 Fitting Sleeve w/ Extension 2
49B 06141 Extension 4
49C 07319 Hexagon Nut 2
50 07158 Nut, Manifold Stud 6
50A 07159 Spring Washer 6
51 06110-0100 Spacer 3
52 06112-0100 Valve Housing 3
53 06965 O-Ring 3
54 04154 Spring Tension Disc 3
55 06357-0100 Plug, 1” BSP 1
56 13150-0100 Plug, 3/4” BSP 1
57 13020 Disc for Crankshaft 1
62 06142 Tin Lid 1
MP4130-3100 & MP4135-3100 SERIES REPAIR KITS
Valve Kit
Part # 09581
Item # Part # Description Qty.
44 07280-0100 Valve Seat 6
44A 06003-0001 O-Ring 6
45 07282 Valve Plate 6
46 07283 Valve Spring 6
47 04153 Spring Tension Cap 3
48A 06965 O-Ring, Plug 3
53 06965 O-Ring 3
54 04154 Spring Tension Disc 3
Seal Kit
Part # 09580
Item # Part # Description Qty.
40 07272 V-Sleeve 9
42B 06736 O-Ring 3
53 06965 O-Ring 3
5
REPAIR INSTRUCTION - MP4130-3100 & MP4135-3100
Disassembly sequence of the GIANT MP4130-3100 & MP4135-3100 Series Pumps
1. With a 27mm wrench,
remove the three discharge plugs (#48) and
three inlet plugs (#42A)
from the manifold (#43).
47 46 45 44A 44
4. Inspect all parts, especially the seating surface of
the valve plate (#45), and replace as necessary.
2. Inspect the plug o-rings
(#48A and #42B) and
replace as necessary.
3. Using a valve puller (available from Snap-On-Tools),
remove the valve assembly (#44 - #47).
5. Remove the six manifold
stud nuts (#50) with a
19mm wrench. Remove
the spring washers (#50A).
Tap the back of the manifold with a rubber mallet to
dislodge and slide it off the
studs (#49).
6. To remove the inlet valve
assembly, insert a 13mm
socket with extension
through the rear of the in-
let manifold (#43) port and
tap it rmly with a ham-
mer. This will force the
tension spring (#46), valve
housing (#52) and the remainder of the inlet valve
assembly out through the
front of the inlet port.
51 44 44A 45 46 52
7. Pull the inlet valve assembly apart for inspection. Any resistance may be overcome by placing the valve housing (#52)
in a brass jawed vise and carefully tapping the back of the
valve plate (#45) with a screwdriver. Remove the spacer
pipe (#51) valve seats (#44), o-ring (#44A), valve plate (#45),
spring (#46), replace them as necessary.
6
36 39 40 41
8. From the back of the
manifold (#43), remove
the packing assembly
(#’s 42, 41, 40, and 39)
by tapping assembly
out from the back to the
front.
10. Note: The following pro-
cedure is only necessary
if a stud bolt (#49) has
been damaged and must
be replaced. To remove
the manifold studs (#49),
place a stud nut (#50),
lock washer (#50A), and
second nut on each stud.
Tighten the nuts against
each other. Hold the front
nut with one wrench, and
remove the stud bolt by
turning the rear nut counterclockwise with another
wrench. To reassemble,
turn the front stud bolt nut
clockwise.
9. Turn the manifold (#43) over and remove the rear v-sleeve
snap ring (#36). Remove rear pressure ring (#39) , rear
v-sleeve (#40) and rear support ring (#41). These parts
should slide out with little resistance. If necessary, a
screwdriver may be used to pry outward. Replace all rubber parts and inspect the metal parts for wear.
11. To remove the ceramic plungers, turn the plunger bolt
(#29C) counterclockwise with a 13mm socket. Use a
steady torque to prevent ceramic plunger sleeve damage. Loosen and remove the plunger bolt assembly
(#29C and #29D) and replace the seal washer (#29D).
31
11a. Inspect the crankcase
oil seals (#31) for evidence
of leaking. If there is oil on
the crankcase (#1) at the
sight of the oil seals, they
must be replaced. The oil
seals are replaced after
removing the crosshead/
plunger assembly (#25) as
described below.
Contact Giant Industries for service school
information. Phone: (419) 531-4600
7
Gear End Disassembly
Note: Make certain that the plungers (29B) have been removed before starting the following sequence.
12. Make sure the oil is drained from the pump before removing the crankcase cover (#4). Remove all screws (#10).
Inspect the crankcase cover o-ring (#5) for damage and replace it as necessary.
13. Remove the connecting rod screws and washers (#’s 24A and 24B) with a 6mm allen wrench. Remove the back
halves of each connecting rod (#24) . Push the connecting rods down as far as possible into the crankcase
(#1) housing. Note that the connecting rod halves are numbered (or colored) and that the numbers (or
colors) must be matched for reassembly.
14. Remove the crankshaft bearing cover screws (#17) with a 13mm wrench. Remove the key (#23) from the
crankshaft (#22).
15. Remove the bearing cover (#14) and any shims (#20A) if any. Remember to replace shims on the same side
of the crankcase (#1) during the reassembly.
16. Steady the pump gear end and, using a rubber mallet, tap the crankshaft (#22) from one side. The far side
bearing race will be removed and the near side race will remain in the crankcase. The roller bearings (#20) will
remain on the crankshaft. When both ends are free, the crankshaft can be removed by hand.
17. To remove the remaining bearing race, place a dowel against the inside edge of the race and tap it out with a
rubber mallet. This is done only if the race wear surface has been damage.
18. Inspect the bearing race removed with the crankshaft (#22) and replace if wear surface is damaged.
19. Note: The following procedure is only necessary if the inspection show s evidence of heavy wear. Inspect
the crankshaft (#22) and bearings (#20) for wear. To remove the roller bearings from the crankshaft, use a three
inch push puller with a pulley attachment. To remount the bearings, tap the bearings down the well-lubricated
crankshaft with the Giant Bearing Tool. Be sure that the bearing is rmly seated.
20. Remove the connecting rod (#24) with the attached crosshead/plunger assembly (#25) from the crankcase (#1)
by pulling it straight out. The oil seals (#31) may now be removed by tapping them out through the front of the
crankcase. Be careful not to damage the snap ring.
21. Inspect the surfaces of the crosshead/plunger assembly (#25) and connecting rods (#24) for heavy scoring or
galling due to poor lubrication. Check for play at the joint between connecting rod crosshead/plunger assembly.
22. To remove the crosshead pin (#28) from the crosshead/plunger assembly (#25), the assembly should be positioned in such a manner to prevent damage to the crosshead when driving the pin out. The crosshead pin can
be driven out by tapping on the tapered side of the pin
Reassembly sequence
Note: Always take time to lubricate all metal and nonmetal parts with a light lm of oil before reassembly. This
step will help ensure a proper t, at the same time it will protect the pump nonmetal parts (elastomers)
from cutting and scoring.
23. Take the crosshead/plunger rod assembly and insert the connecting rod (#24) into the crosshead/plunger assembly (#25). Drive the tapered end of the crosshead pin (#28) into the beveled side of the crosshead and
through the connecting rod completing the assembly.
Note: The crosshead pin should not extend beyond either side of the crosshead in order to prevent damage to
the crosshead bore of the crankcase.
24. Inspect the crankcase crosshead guides for any possible damage.
25. Replace the connecting rod (#24), crosshead/plunger rod assembly (#25) into the crankcase (#1).
26. If removed previously, replace the far side bearing race into the crankcase. Tap with a rubber mallet until the
edges are ush with the crankcase surface.
27. Remove the old crankshaft seal (#15) from the bearing cover (#14). Lubricate the edges of the new seal and
install using the standard Giant Bearing Tool. Remove the bearing tool and tap around the perimeter of the seal
with a rubber mallet to rmly seat the seal. Position the far bearing cover on the crankcase (#1) and insert the
cover bolts (#17). Tighten the cover evenly to the crankcase, setting the bearing into position. Torque the cover
bolts to 125 inch-pounds (14 Nm).
28. Insert the crankshaft (#22) with the mounted bearings (#20) through the near side of the crankcase (#1). Make
certain that the numbers (or colors) or the crankshaft correspond to the numbers (or colors) on the
connecting rods (#24). Reinstall the near side bearing race by inserting it into the crankcase. Supporting the
crankshaft with one hand, tap the race with a rubber mallet until the edge is ush with the crankcase.
8
29. Replace any shims (#20A) and position the bearing cover (#14) as before. Tighten the bearing cover
bolts (#17) evenly to position the bearing race. Torque the bolts to 125 inch-pounds. Once the crankshaft reassembly is complete, oil the crankshaft races freely before replacing the connecting rod (#24)
end caps.
30. Reassemble the connecting rods (#24), matching the numbered (or colored) halves. Torque the connecting rod bolts (#24A) to 250 inch-pounds (28 Nm).
31. To replace the oil seal (#31) apply locktite to the outside edges of the seal and install from the front of
the crankcase (#1). The side of the seal with the spring must face the oil. Make sure that the face of
the seal is ush with the crankcase.
29B 29D 29C
32. Inspect the ceramic plungers (#29B) and replace them if
necessary. Clean the ends of the ceramic and remount
onto the crosshead/plunger assembly. Make certain that
the end of the plunger which is not counter-bored is facing the discharge side of the pump. Install the seal washer (#29D) on the bolt assembly.
33a.Torque the ceramic
plunger bolt assembly to
300 inch-pounds (34 Nm).
If originally removed, reinstall the stud bolts (#49).
34. Install the rear support
ring (#41), rear v-sleeve
(#40), rear pressure ring
(#39). Install the snap ring
(#36).
36. Re asse m bl e the di s-
charge valve assembly
by placing the valve plate
(#45), spring (#46), and
spring retainer (#47) on
top of the valve seat (#44).
Press t together.
33. Clean the bolt threads (#29C), ap-
ply locktite, and remount.
39 40 40 41
35. Reinstall the pressure ring (#39),
v-sleeves (#40) and support ring
(#41) into each plunger bore. Reinstall the tension spring (#42).
9
37. Place the entire discharge
assembly into discharge
port making certain the
assembly is properly seated. Install discharge plug
(#48) and hand tighten.
38. Reassemble the inlet valve
assembly in the reverse
order of step #7. Make
certain all the components
are press t together and
that the spring retainer
(#54) is slightly counter
sunk in the valve housing
(#52). Grease the o-ring
(#53) and install it on to
the valve housing. Reinstall the entire inlet valve
assembly into the manifold
(#43). install the tension
(#42A) and tighten.
plugs
39. Lubricate the plungers
(29B) again and slide the
manifold (#43) gently and
evenly over the plungers.
Press the manifold rmly
into place against the
crankcase (#1). Install
the spring washer (#50A)
and tighten the manifold
stud nuts (#50) to 696
inch-pounds (79 Nm).
MP4130-3100 & MP4135-3100 TORQUE SPECIFICATIONS
Position Item# Description Torque Amount - in.-lbs. (Nm)
17 08095 Hex Screw, Bearing Cover 125 (14)
24A 05349 Hex Screw, Connecting Rod 250 (28)
29C 04150 Bolt, Plunger 300 (34)
50 07158 Nut, Manifold Stud 700 (79)
Pump Mounting Selection Guide
Bushings
01074 24 mm Tapered H Bushing
Pulley & Sheaves
01061 7.75” Cast Iron 1 gr. - AB Section
01062 7.75” Cast Iron - 2 gr. - AB Section
Rails
01160 Plated Steel Channel Rails
(L=5.75”x W=1.00”x h=2.50”)
01161 Plated Steel Channel Rails
(L=5.75”x W=1.00”x H=2.50”)
10
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, Rell 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
Pressure Drop at Gun Restricted discharge plumbing Re-size discharge plumbing to
ow rate of pump
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
Preventative Maintenance Check-List & Recommended Spare Parts List
Check Daily Weekly 50hrs Every Every Every
500 hrs 1500 hrs 3000 hrs
Oil Level/Quality X
Oil Leaks X
Water Leaks X
Belts, Pulley X
Plumbing X
Recommended Spare Parts
Oil Change (1 Quart) X X
Seal Kit (1 kit/pump) X
(See page 5 for kit lit)
Valve Spare Parts (1 kit/pump) X
(See page 5 for kit list)
11
MP4130-3100 & MP4135-3100 DIMENSIONS - Inches (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 mani
folds 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 applica
tions, are warranted for ve 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 modications made by the customer or third party.
6. The operation of pumps and or accessories exceeding the specications 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 war-
ranty 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.
GIANT INDUSTRIES, INC., 900 N. Westwood Ave., Toledo, Ohio 43607
PHONE (419) 531-4600, FAX (419) 531-6836, www.giantpumps.com
© Copyright 2012 Giant Industries, Inc.
07/12 MP4310_MP4135-3100.indd
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