Giant GP5136-5100 User's Manual
Contents
1. Top of pulley towards manifold Maximum Temperature of Pumped Fluids 40 S eite Petre ritenere 60 C Inlet Ports iei tete tete enter en Rh eee ehh eb de thee GE Rae iNT LEER e Eb n ad 3 1 1 2 BSP Discharge e CEET cepas 2 1 BSP KE M 179 ADS tetra ertet 81 Kg Crankcase Oil Capacity eeseeeeeeeenenne UE 4 6 Liters Fluid End Material 4 iere tret RERO RES Eeer 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 GPM 1000PSI 1500PSI 2000PSI 2320 HORSEPOWERRATINGS We recommend a 1 15 service fac The rating shown are the power re tor be specified when select quirements for the pump Gasengine ing an electric motor as the power outputs must be approximately power source To compute twice the pump power requirements specific pump horsepower shown above 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 Specifications Model GP5145 5100 K M 455 GPML ice lene taxes Cree eege 164 6LPM Discharge PresSSUtel eee re i Rr rete E IN TR 100 Bar Crankshatt EE 750RPM Inl t Pressure eerte nee 4 35 to2. 145 PSI 0 3 to 10 Bar Plunger DIAM CCT iecit ctor aE NEE EEEE SUE vr 4mm Plumper SttOke 52 22 enero eter nn reet een Eed Rl C 46mm Crankshaft KE en 35mm x 10mm key Crankshaft Mounting i e ee ERE PR ERE ac iae Either side Shaft Rotation uice rete eege onte irae eegen g da Top of pulley towards manifold Maximum Temperature of Pumped Fluids 140 FE aerea noaa 60 C laolet e enrooconerinoiiidaerir eranen Eie ETA i EAE aiT aea S Aaaa i iE TAAR 3 1 1 2 BSP Discharge POFtS iussu a rne HERE EEUU EN E ET E 2 1 BSP W C18 Dt E E asseeeeses 179 o e 81 Kg Crankcase Oil Capacity serene 1 2 Galician 4 6 Liters Fluid End Material torte Eege SE H NEU E EEE 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 RPM GPM 500PSI 750 PSI 1000 PSI 1450 PSI 400 232 80 120 160 232 600 348 120 180 240 348 HORSEPOWERRATINGS We recommend a 1 15 service fac The rating shown are the power re tor be specified when select quirements for the pump Gasengine ing an electric motor as the power outputs must be approximately power source To compute twice the pump power requirements specific pump horsepower shown above requirements use the follow ing formula HP GPM X PSI 1450
3. 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 GP5136 5100 and GP5145 5100 Pumps Repair Kits Plunger Packing Kits Valve Assembly Kits GP5136 5100 p n 09597 Inlet Valve Kit p n 09231 0100 Item Part Description Oty Item Part Description Qty 35A 07303 O Ring 6 46A 12055 O Ring 1 35B 13286 O Ring 3 46C 13304 0100 Inlet Valve Assy 1 36 13291 0020 Grooved Ring 3 46D 13306 0100 Valve Plate 1 37A 07910 O Ring 6 46E 13307 Valve Spring 1 39 07142 0100 Pressure Ring 3 46F 13308 Spring Tension Cap 1 40 07144 V Sleeve 6 46G 13309 Spacer Pipe 1 48B 07740 O Ring 1 GP5145 5100 p n 09598 Item Pan Description Oty Discharge Valve Kit p n 09232 0100 35A 13286 O Ring 3 Item Part Description Qty 35B 08183 O Ring 3 47A 13289 O Ring 1 40 13294 Sleeve 6 47C 13313 Discharge Valve Assy 1 40A 06146 Grooved Ring 3 47D 13306 0100 Valve Plate 1 47E 13307 Valve Spring 1 Oil Seal Kit p n 09230 47F 13308 Spring Tension Cap 1 Item Part Description Qty 48B 07740 O Ring 1 31 13284 Oil Seal 3 GP5136 5100 amp GP5145 5100 Pump Torque Specifications Position Item Description Torque Amount ft Ibs 24 13276 Connecting Rod Assy 26 29C 07131 0100 Tension Screw Plunger 26 48A 07008 Inner Hexagon Screw Plug 35 49 13339 Inner Hexagon Screw Valve Casing 85 Preventative Maintenance Check List amp Recommended Spare Part
4. 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 Ibs 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 Ibs Repair Instructions GP5136 5100 and GP5145 5100 Pumps To Disassemble Gear End 1 Loosen inner hexagon s
5. Spacer Pipe Discharge Valve Assy O Ring Discharge Valve Seat Valve Plate Valve Spring Spring Tension Cap Plug Inner Hexagon Screw O Ring Pressure Ring Inner Hexagon Screw Disc for Crankshaft Hexagon Screw Plug 1 BSP Plug 1 1 2 BSP Eye Bolt A ra RR D L L FA L L L L L L L L L L L L L L L L ra WW O9 Lu PUMP SYSTEM TROUBLESHOOTING CHART MALFUNCTION CAUSE REMEDY Replace packing seals ET US S DE u Check inlet lines of pump for restrictions Cavitation or leakage Check for proper operation I Waterin rnkeass High Humidit Reduce oil change intervals Worn Seals Replace seals Replace bearings Refill crankcase with recommended oil Check inlet lines for restrictions and or proper sizing Worn bearings Noisy Operating Cavitation Worn packing Replace packing Check system for stoppage air leaks Rough Pulsating correctly sized inlet plumbing to pump Operation with Pressure Drop nm Check inlet lines for restrictions and or Cavitation E proper sizing Re size discharge plumbing to flow rate of Pressure drop at gun Restricted discharge plumbing UID Excessive leakage High Crankcase Wrong Grade of Oil Giant oil is recommended Temperature mproper amount of oil in crankcase Adjust oil level to proper amount Repair Instructions GP5136 5100 and GP5145 5100 Pumps Note Always take time to lubricate all metal and nonmetal parts with a light fil
6. Triplex Ceramic Plunger Pump Operating Instructions Manual Models GP5136 5100 amp GP5145 5100 Contents Installation Instructions page 2 Pump Specifications pages 3 4 Kits Torque Specs page 5 Recommended Maintenance page 5 Exploded View Parts List pages 6 7 Trouble Shooting page 8 Repair Instructions pages 9 10 Dimensions page 11 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 installa tion 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 inclina tion 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 spik
7. crews 49 for the valve casing 43 with an allen wrench Carefully remove valve casing from the crankcase 1 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 Loosen hexagon screws 17 for the bearing covers 14 with a wrench and remove bearing cover 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 N Un A 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 ON 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 Fitthe crankshaft 22 with pressed on bearing parts through the bearing hole on th
8. e 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 1 mm each The crankshaft 22 should turn easily with very little clearance Tighten inner hexagon screws on the connecting rods 24 to 26 ft Ibs 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 Pump Dimensions GP5136 5100 and GP5145 5100 Pumps Inches mm rg egoz dg ILL SHOq Io dSd ub XZ syuog eBJeuosiq ogg L 6L 092 PZ Ol OIZ 42 8 Orc 696 ZEE NI0 8W SQ Bunau A e in Res g T3 D ESSE SL N e KS ogr 6 81 DIG 5889 NIC 9X6X01v e M S M 11 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 i
9. es 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 connec tions and other system areas The use of a dampener with Giant Industries Inc pumps is optional although recommended by Giant IMPORTANT OPERATING CONDITIONS Failure to comply with any of these conditions invalidates the warranty 1 Prior to initial operation add oil to crank case so that oil level is between the two lines on the oil dipstick DO NOT OVERFILL SAE 80 or SAE 90 Industrial Gear p n 01154 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 Industries Inc to further reduce system pulsa tion 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 desig nated 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 ob tained from the charts on pages 3 4 6 Before beginning operation of your pump ing system remember Check that the crank case and seal areas have been properly lubri cated per recom
10. es 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 EXPRESS OR IMPLIED INCLUDING WITHOUT LIMITATION ANY WARRAN 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 Phone 419 531 4600 FAX 419 531 6836 www giantpumps com Copyright 2004 Giant Industries Inc 9 04 GP5136 5100 GP5145 5100 PMD
11. m of oil before reassembly This step will ensure proper fit at the same time protecting the pump s nonmetal parts Oe 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 Ibs 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
12. mended schedules Do not run the pump dry for extended periods of time Cavitation will result in severe damage Al ways 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 opera tion 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 Indus tries 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 419 531 4600 Specifications Model GP5136 5100 iunc oa ERNE EEA EE tae ten ate 39 8 GPM RE 127 8 LPM Discharge PreSSUte euer hetero 2320 PSI iiien trt 160 Bar Crank sha ge E 910 RPM Inlet Pressure tene 4 35 to 145 PSI 0 3 to 10 Bar Pl nbser Diameter be eegene eeh gegen geen EE Rr RS Dee E ege eege degt 36mm Plonger Stroke enr eere eene eine saepe rie Larva tae Te erem tenent 46mm Crankshaft HEES EE 35mm x 10mm key Crankshaft Mounting eerte Here ee v d ERES HEX FEE ETE EENS Either side Shatt E o p
13. n 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 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 Normal wear and tear to standard wear parts Use of repair parts other than those manufactured or authorized by Giant Improper use of the product as a component part Changes or modifications made by the customer or third party oa fF wh 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 Industri
14. osshead Assy Crosshead Pin Centering Sleeve Plunger Pipe GP5136 5100 Plunger Pipe GP5145 5100 Tension Screw Steel Ring Oil Scraper Radial Shaft Seal Seal Sleeve GP5136 5100 Seal Sleeve GP5145 5100 O Ring GP5136 5100 O Ring GP5145 5100 O Ring GP5136 5100 O Ring GP5145 5100 Grooved Ring GP5136 5100 Seal Case GP5136 5100 Pressure Ring Drip Return GP5145 5100 LA L U2 L L QN L L U2 L U2 L L 4 La L L Lu ra tA F2 O0 ONNN RR P P ra ka ka Fa ba ka o LA QTY ITEMPART 37A 07910 39 07142 0100 39 13292 40 07144 40 13294 40A 06146 41 07146 0100 41 13295 42 07147 42 13297 42A 13298 0100 43 13300 5000 44 06589 45 07204 0100 46 13302 0100 12055 13304 0100 13306 0100 13307 13308 13309 47 13311 0100 13289 13313 13306 0100 13307 13308 48 13316 0100 07008 07740 07232 49 13339 52 13362 53 13358 54 13321 0100 55 13322 0100 56 07623 DESCRIPTION QTY O Ring GP5136 5100 Only 6 Pressure Ring GP5136 5100 3 Pressure Ring GP5145 5100 3 V Sleeve GP5 136 5100 6 Sleeve GP5145 5100 6 Grooved Ring GP5145 5100 Only 3 Sleeve Support Ring GP5136 5100 3 Sleeve Support Ring GP5145 5100 Tension Spring GP5136 5100 Tension Spring GP5145 5100 Spring Guide GP5136 5100 only Valve Casing 316 S S Plug 1 8 BSP Steel Seal Ring Inlet Valve Assy O Ring Inlet Valve Seat Valve Plate Valve Spring Spring Tension Cap
15. s List Every Every Every 500 1500 3000 Hours Hours Hours Oil Level Quality PX o p l1 1 o Oil Leaks OX bj f f WaterLeaks LZ TTT Belts Pulleys 1X p p D Plumbing Lp x Soc qd cb o d 3 Check Daily Weekly 50 Hours Recommended Spare Parts List prowmetouganouss x fx S p See page 7 for SS list AEN Oll Spare Parts 1kit pump See page 7 for kit list Valve Spare Parts 1kit pbump See page 7 for kit list Exploded View GP5136 5100 and GP5145 5100 Pumps osr e der CoO Lo 8r 7 ver GP5136 5100 and GP5145 5100 Pumps Spare PARTS LIST ITEMPART 1 13266 2 13000 3 07841 0100 4 13267 5 13268 8 07105 9 01009 10 07008 11 06725 12 07703 13 13269 14 13271 15 13272 16 08182 17 13358 18 06725 20 13206 20A 13207 21 13273 22 13274 23 13275 24 13276 25 13280 28 13281 29A 07125 29B 07130 29B 13283 29C 07131 0100 29D 07161 0100 30 13282 31 13284 35 13288 0100 35 13287 0100 35A 07303 35A 13286 35B 13286 35B 08183 36 13291 0020 37 06574 0100 37 06145 0100 DESCRIPTION Crankcase Oil Filler Plug Assembly Oil Sight Glass Assy 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 Crankshaft Fitting Key Connecting Rod Assy Cr
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