Triplex Ceramic
Plunger Pump
Operating Instructions/
Manual
Models
GP5132, GP5136 & GP5145
Contents:
InstallationInstructions:
PumpSpecifications:
page 2
pages 3-5
Parts List/Exploded View: pages 6-7
Kits/TorqueSpecs:
TroubleShooting:
RepairInstructions:
Dimensions:
page 8
page 9
page 10-11
back page
WarrantyInformationback page
Specifications
Model GP5132
Volume ................................................................................................... Up to 29 GPM
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.
HORSEPOWER RATINGS:
The rating shown are the power
requirements for the pump. Gas
GP5132 HORSEPOWER
REQUIREMENTS
1OOO 15OO 2OOO 25OO
3000
PSI
engine power outputs must be
approximately twice the pump
power requirements shown above.
RPM
600
GPM
17.4
20.3
26.1
29
PSI
PSI
PSI
PSI
12
18
24
30
36
42
54
60
We recommend a 1.15 service factor
be specified when selecting an
electric motor as the power source.
To compute specific pump horse-
power requirements, use the follow-
ing formula:
700
14
18
20
21
27
30
28
36
40
35
45
50
900
1000
HP = (GPM X PSI) / 1450
SPECIAL NOTE:
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%.
3
Specifications
Model GP5136
Volume ................................................................................................... Up to 35 GPM
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.
HORSEPOWER RATINGS:
The rating shown are the power
requirements for the pump. Gas
GP5136 HORSEPOWER
REQUIREMENTS
1OOO 15OO
1800
PSI
2000
PSI
2200
PSI
engine power outputs must be
approximately twice the pump
power requirements shown above.
RPM
700
750
800
850
945
GPM
26
PSI
PSI
18
27
33
35
36.3
39
39.4
42.5
45.5
48.6
53.1
We recommend a 1.15 service factor
be specified when selecting an
electric motor as the power source.
To compute specific pump horse-
power requirements, use the follow-
ing formula:
28
19
21
29
31
30
37
41
32
22
33
40
44
35
24.1
36.2
43.4
48.2
HP = (GPM X PSI) / 1450
SPECIAL NOTE:
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%.
4
Specifications
Model GP5145
Volume ................................................................................................... Up to 43.3 GPM
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.
HORSEPOWER RATINGS:
The rating shown are the power
requirements for the pump. Gas
GP5145 HORSEPOWER
REQUIREMENTS
1OOO
PSI
1100
PSI
1300
PSI
1500
PSI
engine power outputs must be
approximately twice the pump
power requirements shown above.
RPM
550
600
650
700
750
GPM
31.9
34.9
37.8
40.6
43.3
22
24.1
26
24.2
26.5
28.7
30.8
32.8
28.6
31.3
33.9
36.4
38.8
33
36.1
39.1
42
We recommend a 1.15 service factor
be specified when selecting an
electric motor as the power source.
To compute specific pump horse-
power requirements, use the follow-
ing formula:
28
29.9
44.8
HP = (GPM X PSI) / 1450
SPECIAL NOTE:
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%.
5
GP5100 Series PARTS LIST
ITEM PART DESCRIPTION
QTY.
1
1
1
1
1
1
1
4
4
1
1
2
2
2
8
8
2
5
1
1
1
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
ITEM PART DESCRIPTION
37B 07653 O-Ring(GP5132)
QTY.
1
13266 Crankcase
3
3
3
3
6
6
6
2
3
4
5
13000 OilFillerPlugAssembly
07186 OilSightGlassAssy.
13267 CrankcaseCover
13268 O-Ring
39
39
39
40
40
40
41
13026 PressureRing(GP5132)
07142 PressureRing(GP5136)
13293 PressureRing(GP5145)
13027 V-Sleeve(GP5132)
07144 V-Sleeve(GP5136)
13294 V-Sleeve(GP5145)
13028 SleeveSupportRing
(GP5132)
8
07105 OilDipStick
9
01009 O-Ring,DipStick
13270 InnerHexagonScrew
13134 SpringWasher
07703 DrainPlugG3/4"
13269 Gasket,DrainPlug
13271 BearingCover
13272 RadialShaftSeal
08182 O-Ring
10
11
12
13
14
15
16
17
18
20
3
3
41
41
07146 SleeveSupportRing
(GP5136)
13296 SleeveSupportRing
(GP5145)
3
3
3
3
42
42
42
07173 TensionSpring(GP5132)
07147 TensionSpring(GP5136)
13297 TensionSpring(GP5145)
13358 Hexagon Screw
13134 SpringWasher
13206 TaperRollerBearing
42A 13298 SpringGuide(GP5136only) 3
20A 13207 FittingDisc(Shim)
43
46
13300 ValveCasing
13302 SuctionValveAssy.
1
3
21
22
23
24
25
28
13273 ShaftProtector
13274 Crankshaft
13275 FittingKey
13276 ConnectingRodAssy.
13279 CrossheadAssy.
13281 CrossheadPin
46A 12055 O-Ring
46B 08059 O-Ring
1*
1*
1*
1*
1*
1*
1*
3
1*
1*
1*
1*
1*
1*
3
12
3
3
8
1
1
1
2
46C 13304 SuctionValveSeat
46D 13306 ValvePlate
46E 13307 ValveSpring
46F 13308 SpringTensionCap
46G 13309 Spacer Pipe
29A 07125 CenteringSleeve
29B 13022 PlungerPipe(GP5132)
29B 07130 PlungerPipe(GP5136)
29B 13283 PlungerPipe(GP5145)
29C 07131 TensionScrew
47
13311 DischargeValveAssy.
47A 13312 O-Ring
47B 07700 O-Ring
47C 13314 DischargeValveSeat
47D 13306 ValvePlate
47E 13307 ValveSpring
47F 13308 SpringTensionCap
29D 07755 OilScraper
30
31
35
35
35
13282 CopperRing
13284 RadialShaftSeal
13359 SealSleeve(GP5132)
13288 SealSleeve(GP5136)
13287 SealSleeve(GP5145)
48
13316 Plug
48A 07008 InnerHexagonScrew
48B 07740 O-Ring
48C 07232 PressureRing
35A 13289 O-Ring(GP5136)
35A 13286 O-Ring(GP5145)
35B 08183 O-Ring
49
52
53
54
55
13362 InnerHexagonScrew
13363 DiscforCrankshaft
13358 Hexagon Screw
13321 PlugG1"
36
36
36
37
13360 GroovedRing(GP5132)
13291 GroovedRing(GP5136)
13290 GroovedRing(GP5145)
13361 Seal Case (GP5132)
13322 PlugG1-1/2"
37A 07700 O-Ring(GP5132)
6
Exploded View - GP5100 Series
7
GP5100 SERIES REPAIR KITS
Valve Assembly Kits
Plunger Packing Kits
GP5132
#09290
Inlet Valve Kit, GP5100 Series, #09231
Qty.
3
3
Part #
Description
O-Ring
Grooved Ring
V-Sleeve
Qty.
1
1
1
1
Part #
12055
08059
13304
13306
13307
Description
O-Ring
O-Ring
Valve Seat
Valve Plate
Valve Spring
08183
13360
13027
6
1
GP5136
#09229
Qty.
3
3
3
6
Part #
Description
O-Ring
Discharge Valve Kit, GP5100 Series, # 09232
13289
08183
13291
07144
O-Ring
Grooved Ring
V-Sleeve
Qty.
1
1
1
1
Part #
13312
07700
13314
13306
13307
Description
O-Ring
O-Ring
Valve Seat
Valve Plate
Valve Spring
GP5145
#09228
1
Qty.
3
3
3
6
Part #
Description
O-Ring
13286
08183
13290
13294
O-Ring
Grooved Ring
V-Sleeve
Oil Seal Kit
GP5100 Series, #09230
Qty.
3
Part #
13284
Description
Oil Seal
GP5100 SERIES TORQUE SPECIFICATIONS
Position
Item#
13276
07131
07008
13362
Description
Torque Amount (ft.-lbs)
24
29C
48A
49
Connecting Rod Assy.
26
26
35
85
Tension Screw, Plunger
Inner Hexagon Screw, Plug
Inner Hexagon Screw, Valve Casing
8
PUMPSYSTEMMALFUNCTION
MALFUNCTION
CAUSE
REMEDY
ThePressureand/
ortheDelivery
Drops
Wornpackingseals
Brokenvalvespring
Beltslippage
WornorDamagednozzle
Fouleddischargevalve
Fouledinletstrainer
Worn or Damagedhose
WornorPluggedreliefvalveonpump
Cavitation
Replacepackingseals
Replacespring
TightenorReplacebelt
Replacenozzle
Cleanvalveassembly
Cleanstrainer
Repair/Replacehose
Clean,Reset,andReplacewornparts
Checksuctionlinesoninletof
pumpforrestrictions
Unloader
Checkfor proper operation
Waterincrankcase
NoisyOperation
Highhumidity
Wornseals
Reduceoilchangeinterval
Replaceseals
Wornbearings
Cavitation
Replacebearings,Refillcrankcase
oilwith recommendedlubricant
Checkinletlinesforrestrictions
and/orpropersizing
Rough/Pulsating
Operationwith
PressureDrop
Wornpacking
Inletrestriction
Replacepacking
Checksystemfor stoppage, air
leaks,correctlysized inlet
plumbingtopump
Accumulatorpressure
Unloader
Cavitation
Recharge/Replaceaccumulator
Checkfor proper operation
Checkinletlinesforrestrictions
and/orpropersize
PumpPressureas
atgun
Restricteddischargeplumbing
Re-sizedischargeplumbingtoDrop
flowrateofpump
Rated, Pressure
Excessive
Leakage
Wornplungers
Replaceplungers
Wornpacking/seals
Excessivevacuum
Crackedplungers
Inletpressuretoohigh
AdjustorReplacepackingseals
Reducesuctionvacuum
Replaceplungers
Reduceinletpressure
High Crankcase
Temperature
Wrong Grade of oil
Improper amount of oil in crankcase
Giant oil is recommended
Adjust oil level to proper amount
9
REPAIRINSTRUCTIONS
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 non-
metal 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 dam-
age to the front surface of the Plunger. If these conditions are ignored, the Plunger Pipe will prob-
ably 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. Connect-
ing 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
OUTLET
10mm X 63mm Key
18.9"
DIMENSIONS
4.61"
13.9"
3.06"
7.68"
20.6"
9.69"
INLET
8.27"
10.2"
19.1"
2.17"
GIANTINDUSTRIESLIMITEDWARRANTY
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 requiredprior 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 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,EXPRESSORIMPLIED,INCLUDINGWITHOUTLIMITATIONANYWARRAN-
TIES OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE AND ALL SUCH
WARRANTIESAREHEREBYDISCLAIMEDANDEXCLUDEDBYTHEMANUFACTURER.
GIANT INDUSTRIES, INC., 900 N. Westwood Ave., P.O. Box 3187
3/98GP5100.PM6
Ó Copyright 1996 Giant Industries, Inc.
|