Giant Automobile Parts GP5136 5100 User Manual

Triplex Ceramic  
Plunger Pump  
OperatingInstructions/  
Manual  
Models  
GP5136-5100 & GP5145-5100  
Contents:  
Installation Instructions:  
Pump Specifications:  
Kits/Torque Specs:  
Recommended Maintenance:  
Exploded View/Parts List:  
Trouble Shooting:  
page 2  
pages 3-4  
page 5  
page 5  
pages 6-7  
page 8  
Repair Instructions:  
Dimensions:  
pages 9-10  
page 11  
WarrantyInformation  
back page  
 
Specifications  
Model GP5136-5100  
Volume ............................................................................... 33.8 GPM ...................................... 127.8 LPM  
Discharge Pressure.............................................................. 2320 PSI ............................................160 Bar  
Crankshaft Speed .......................................................................................................................... 910 RPM  
Inlet Pressure ...........................................................-4.35 to 145 PSI ..................................-0.3 to 10 Bar  
Plunger Diameter ...................................................................... 1.42” .............................................. 36mm  
Plunger Stroke ........................................................................... 1.81” .............................................. 46mm  
Crankshaft Diameter .................................................................................................... 35mm x 10mm key  
Crankshaft Mounting .................................................................................................................. Either side  
Shaft Rotation ...........................................................................................Top of pulley towards manifold  
o
o
Maximum Temperature of Pumped Fluids ........................... 140 F ................................................ 60 C  
Inlet Ports ...............................................................................................................................(3) 1-1/2" BSP  
Discharge Ports ........................................................................................................................... (2) 1" BSP  
Weight .................................................................................... 179 lbs. ...............................................81 Kg  
Crankcase Oil Capacity ........................................................ 1.2 Gal. ......................................... 4.6 Liters  
Fluid End Material ............................................................................ Nickel-plated spherodical 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.  
GP5136-5100 Horsepower Requirements  
RPM  
700  
750  
800  
850  
910  
GPM  
26.0  
27.9  
29.7  
31.6  
33.8  
1000 PSI 1500 PSI 2000 PSI  
2320  
41.6  
44.6  
47.5  
50.5  
54.1  
17.9  
19.2  
20.5  
21.8  
23.3  
26.9  
28.8  
30.7  
32.7  
35.0  
35.9  
38.4  
41.0  
43.5  
46.6  
HORSEPOWERRATINGS:  
The rating shown are the power re-  
quirements for the pump. Gas engine  
power outputs must be approximately  
twice the pump power requirements  
shown above.  
We recommend a 1.15 service fac-  
tor be specified when select-  
ing an electric motor as the  
power source. To compute  
specific pump horsepower  
requirements, use the follow-  
ing formula:  
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 GP5145-5100  
Volume .................................................................................. 43.5GPM ..........................................164.6LPM  
Discharge Pressure........................................................ 1450 PSI ............................................ 100 Bar  
Crankshaft Speed ......................................................................................................................... 750RPM  
Inlet  
Pressure ................................................... -4.35 to 145 PSI ................................ -0.3 to 10 Bar  
Plunger Diameter .................................................................... 1.77” ................................................. 45mm  
Plunger Stroke ........................................................................ 1.81” ................................................. 46mm  
Crankshaft Diameter ................................................................................................... 35mm x 10mm key  
Crankshaft Mounting ........................................................................................................ Either side  
Shaft Rotation ............................................................................... Top of pulley towards manifold  
Maximum Temperature of Pumped Fluids ........................ 140 oF ................................................ 60 oC  
Inlet Ports ............................................................................................................................(3)1-1/2" BSP  
Discharge Ports ......................................................................................................................... (2)1"BSP  
Weight ................................................................................... 179 lbs. .................................................81Kg  
Crankcase Oil Capacity ................................................... 1.2 Gal. ...................................... 4.6 Liters  
Fluid End Material ............................................................................ Nickel-plated spherodical 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.  
GP5145-5100 Horsepower Requirements  
RPM  
400  
500  
600  
700  
750  
GPM  
23.2  
29.0  
34.8  
40.6  
43.5  
500 PSI  
8.0  
10.0  
12.0  
14.0  
15.0  
750 PSI 1000 PSI 1450 PSI  
12.0  
15.0  
18.0  
21.0  
22.5  
16.0  
20.0  
24.0  
28.0  
30.0  
23.2  
29.0  
34.8  
40.6  
43.5  
We recommend a 1.15 service fac-  
tor be specified when select-  
ing an electric motor as the  
power source. To compute  
specific pump horsepower  
requirements, use the follow-  
ing formula:  
HORSEPOWERRATINGS:  
The rating shown are the power re-  
quirements for the pump. Gas engine  
power outputs must be approximately  
twice the pump power requirements  
shown above.  
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
 
GP5136-5100 and GP5145-5100 Pumps Repair Kits  
Plunger Packing Kits  
GP5136-5100 (p/n 09597)  
Valve Assembly Kits  
Inlet Valve Kit (p/n 09231-0100)  
Item  
35A  
35B  
36  
37A  
39  
Part #  
07303  
13286  
13291-0020  
07910  
Description  
O-Ring  
O-Ring  
Grooved Ring  
O-Ring  
Qty.  
6
3
3
6
Item  
46A  
46C  
46D  
46E  
46F  
46G  
48B  
Part #  
12055  
13304-0100  
13306-0100  
13307  
13308  
13309  
07740  
Description  
O-Ring  
Qty.  
1
1
1
1
1
1
1
Inlet Valve Assy.  
Valve Plate  
Valve Spring  
Spring Tension Cap  
Spacer Pipe  
O-Ring  
07142-0100  
07144  
Pressure Ring  
V-Sleeve  
3
6
40  
GP5145-5100 (p/n 09598)  
Discharge Valve Kit (p/n 09232-0100)  
Item  
35A  
35B  
40  
Part #  
Description  
O-Ring  
O-Ring  
Sleeve  
Qty.  
3
3
6
3
13286  
08183  
13294  
06146  
Item  
47A  
47C  
47D  
47E  
47F  
Part #  
13289  
13313  
13306-0100  
13307  
Description  
O-Ring  
Discharge Valve Assy. 1  
Valve Plate  
Valve Spring  
Spring Tension Cap  
Qty.  
1
40A  
Grooved Ring  
1
1
1
13308  
Oil Seal Kit (p/n 09230)  
48B  
07740  
O-Ring  
1
Item  
31  
Part #  
13284  
Description  
Oil Seal  
Qty.  
3
GP5136-5100 & GP5145-5100 Pump Torque Specifications  
Position  
Item#  
Description  
Torque Amount (ft.-lbs)  
24  
29C  
48A  
49  
13276  
Connecting Rod Assy.  
26  
26  
35  
85  
07131-0100 Tension Screw, Plunger  
07008  
13339  
Inner Hexagon Screw, Plug  
Inner Hexagon Screw, Valve Casing  
Preventative Maintenance Check-List & Recommended Spare Parts List  
Every  
1500  
Hours  
Every  
3000  
Hours  
Every 500  
Hours  
Check  
Daily  
Weekly 50 Hours  
Oil Level/Quality  
Oil Leaks  
Water Leaks  
Belts/Pulleys  
Plumbing  
X
X
X
X
X
Recommended Spare Parts List  
X
X
Oil Change (1 Quart) p/n 01153  
Seal Spare Parts (1kit/pump)  
See page 7 for kit list  
X
X
OIl Spare Parts (1kit/pump) See  
page 7 for kit list  
Valve Spare Parts (1kit/pump)  
See page 7 for kit list  
X
5
 
Exploded View - GP5136-5100 and GP5145-5100 Pumps  
6
 
GP5136-5100 and GP5145-5100 Pumps Spare PARTS LIST  
ITEMPART  
DESCRIPTION  
Crankcase  
Oil Filler Plug Assembly  
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
6
3
3
3
3
3
ITEMPART  
37A 07910  
DESCRIPTION  
O-Ring (GP5136-5100 Only)  
QTY.  
1
2
13266  
13000  
6
3
3
6
6
39  
39  
40  
40  
07142-0100 Pressure Ring (GP5136-5100)  
3
07841-0100 Oil Sight Glass Assy.  
13292  
07144  
13294  
Pressure Ring (GP5145-5100)  
V-Sleeve (GP5136-5100)  
Sleeve (GP5145-5100)  
Grooved Ring  
4
5
8
9
13267  
13268  
07105  
01009  
07008  
06725  
07703  
13269  
13271  
13272  
08182  
13358  
06725  
13206  
Crankcase Cover  
O-Ring  
Oil Dip Stick  
O-Ring, Dip Stick  
Inner Hexagon Screw  
Spring Washer  
Drain Plug, 3/4" BSP  
Gasket, Drain Plug  
Bearing Cover  
Radial Shaft Seal  
O-Ring  
Hexagon Screw  
Spring Washer  
Taper Roller Bearing  
Fitting Disc (Shim)  
Shaft Protector  
40A 06146  
(GP5145-5100 Only)  
3
3
10  
11  
12  
13  
14  
15  
16  
17  
18  
20  
41  
41  
07146-0100 Sleeve Support Ring  
(GP5136-5100)  
Sleeve Support Ring  
(GP5145-5100)  
Tension Spring (GP5136-5100)  
Tension Spring (GP5145-5100)  
13295  
3
3
3
42  
42  
07147  
13297  
42A 13298-0100 Spring Guide (GP5136-5100 only) 3  
43  
44  
45  
46  
13300-5000 Valve Casing, 316 S.S.  
06589 Plug, 1/8” BSP  
07204-0100 Steel Seal Ring  
13302-0100 Inlet Valve Assy.  
1
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
12  
3
3
8
1
1
1
2
1
20A 13207  
21  
22  
23  
24  
25  
28  
13273  
13274  
13275  
13276  
13280  
13281  
46A 12055  
46C 13304-0100 Inlet Valve Seat  
46D 13306-0100 Valve Plate  
46E 13307  
46F 13308  
46G 13309  
O-Ring  
Crankshaft  
Fitting Key  
Connecting Rod Assy.  
Crosshead Assy.  
Crosshead Pin  
Centering Sleeve  
Plunger Pipe (GP5136-5100)  
Plunger Pipe (GP5145-5100)  
Valve Spring  
Spring Tension Cap  
Spacer Pipe  
29A 07125  
29B 07130  
29B 13283  
29C 07131-0100 Tension Screw  
29D 07161-0100 Steel Ring  
47  
13311-0100 Discharge Valve Assy.  
47A 13289  
47C 13313  
47D 13306-0100 Valve Plate  
47E 13307  
47F 13308  
O-Ring  
Discharge Valve Seat  
Valve Spring  
Spring Tension Cap  
30  
31  
35  
35  
13282  
13284  
Oil Scraper  
Radial Shaft Seal  
48  
13316-0100 Plug  
13288-0100 Seal Sleeve (GP5136-5100)  
13287-0100 Seal Sleeve (GP5145-5100)  
48A 07008  
48B 07740  
48C 07232  
Inner Hexagon Screw  
O-Ring  
Pressure Ring  
Inner Hexagon Screw  
Disc for Crankshaft  
Hexagon Screw  
35A 07303  
35A 13286  
35B 13286  
35B 08183  
O-Ring (GP5136-5100)  
O-Ring (GP5145-5100)  
O-Ring (GP5136-5100)  
O-Ring (GP5145-5100)  
49  
52  
53  
54  
55  
56  
13339  
13362  
13358  
36  
37  
37  
13291-0020 Grooved Ring (GP5136-5100)  
06574-0100 Seal Case (GP5136-5100)  
06145-0100 Pressure Ring, Drip Return  
(GP5145-5100)  
13321-0100 Plug, 1" BSP  
13322-0100 Plug, 1-1/2" BSP  
07623  
Eye Bolt  
3
7
 
PUMP SYSTEM TROUBLESHOOTING CHART  
MALFUNCTION  
CAUSE  
REMEDY  
Worn packing seals  
Broken valve springs  
Belt slippage  
Worn or Damaged nozzle  
Fouled discharge valve  
Replace packing seals  
Replace springs  
Tighten or replace belt  
Replace nozzle  
The Pressure and/  
Clean valve assembly  
or the delivery Drops  
Worn or plugged relief valve on pump Clean, Reset, and Replace worn parts  
Check inlet lines of pump for restrictions  
Cavitation  
or leakage  
Unloader  
Check for proper operation  
High Humidity  
Worn Seals  
Reduce oil change intervals  
Replace seals  
Water in Crankcase  
Noisy Operating  
Replace bearings, Refill crankcase with  
recommended oil  
Check inlet lines for restrictions and/or  
proper sizing  
Worn bearings  
Cavitation  
Worn packing  
Inlet restriction  
Replace packing  
Check system for stoppage, air leaks,  
correctly sized inlet plumbing to pump  
Recharge or replace accumulator  
Check for proper operation  
Check inlet lines for restrictions and/or  
proper sizing  
Rough/Pulsating  
Operation with  
Pressure Drop  
Accumulator pressure  
Unloader  
Cavitation  
Re-size discharge plumbing to flow rate of  
pump  
Pressure drop at gun  
Excessive leakage  
Restricted discharge plumbing  
Worn plungers  
Replace plungers  
Worn packing/seals  
Excessive vacuum  
Cracked plungers  
Inlet pressure too high  
Adjust or replace packing seals  
Reduce inlet vacuum  
Replace plungers  
Reduce inlet pressure  
High Crankcase  
Temperature  
Wrong Grade of Oil  
Improper amount of oil in crankcase  
Giant oil is recommended  
Adjust oil level to proper amount  
8
 
Repair Instructions - GP5136-5100 and GP5145-5100 Pumps  
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 and the valve seat 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 inlet valve seat (46C) remains in the valve  
casing (43), remove it with a slide hammer. Check the sealing areas of the inlet valve plate (46D)  
and the inlet 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 ( GP5136-5100 only) (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 as  
well as 37B in GP5136-5100 only) 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 steel ring (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.  
9
 
Repair Instructions - GP5136-5100 and GP5145-5100 Pumps  
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. Drain oil from the crankcase (1) by removing drain plug (12) with a 3/4" wrench.  
3. Loosen inner hexagon screws (10) for the crankcase cover (4) with an allen wrench and remove  
crankcase cover.  
4. Loosen hexagon screws (17) for the bearing covers (14) with a wrench and remove bearing cover.  
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.  
Important!!  
The 1/2” BSP connection in the crankcase serves the purpose of draining leakage water.  
The connection should not be closed. See the drawing below.  
10  
 
Pump Dimensions - GP5136-5100 and GP5145-5100 Pumps - Inches (mm)  
11  
 
GIANT INDUSTRIES LIMITEDWARRANTY  
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 prior 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  
WARRANTIES ARE HEREBY DISCLAIMED AND EXCLUDED BY THE MANUFACTURER.  
GIANT INDUSTRIES, INC. 900 N. Westwood Ave., P.O. Box 3187, Toledo, Ohio 43607  
Copyright 2004 Giant Industries, Inc.  
9/04 GP5136-5100_GP5145-5100.PMD  
 

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