Giant GP5132 User's Manual
Contents
1. 41 Sleeves 40 and Grooved Rings 36 Replace worn parts as necessary 2 Ifa 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 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 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 Ibs 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 allen2. 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 DIMENSIONS 10mm X 638mm Key OUTLET 18 9 T fe reen Ee EE SE ie DS M8 DIN 332 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 One 1 year from the date of shipment for all other Giant industrial and consumer pumps 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 item
3. 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 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 Ifthe 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 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 of the guides in the crankcase and over the plunger pipes 29B Remove Sleeve Support Ring
4. 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
5. 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 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 419 531 4600 2 Specifications Model GP5132 Kr ee ea ges E ee Up to 29 GPM DIG CHa Se EE Up to 3000 PSI SPC Oi uiassot anaes EERO OE AA AE AT AA O AEE A A AATE Up to 1000 RPM le EE aa Up to 145 PSI Plein en REH 32 mm PIU GEES SUR OK EE 46mm Cratvkshalt Diameter E 35mm x 10mm key Ee EK S cecina Either side GHEET Top of pulley towards manifold Temperature of Pumped PGS EE Up to 140 F MU EE ere asics los susan sa EAEE IEO E TOAT 3 1 1 2 BSP Do Ee SOON ats cesar as oa nnaa eae crsasne ates eens meee 2 1 BSP Eeer 179 Ibs Consult the factory for special requirements that must be met if the pump is to operate be
6. NTS requirements for the pump Gas esea ea PSI PSI PSI PSI 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 horse power 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 KT Up to 43 3 GPM IR BRC SGU EE Up to 1500 PSI DCC E Up to 750 RPM aN tee ade canter dd Up to 145 PSI Pliner Drain eter EE 45mm PIMC e ee EEN 46mm Crankshait RE E 35mm x 10mm key Crank Pan WOUNDS serria Either side SAE ROON asa T T Top of pulley towards manifold Temperature of Pumped PGS EE Up to 140 F MU E a E EAE A AE EE E E E EAEE IEO E TOAT 3 1 1 2 BSP Do EPO ats cesar as oa nnaa eae crsasne ates eens meee 2 1 BSP Eeer 179 Ibs 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 GP5145 HORSEPOWER The rating shown are the power REQUIREMENTS requirements for the pump Gas ol Pal E es 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 h
7. P5132 O Ring GP5132 OTY LO WW WW WW WW Lu Lu Lu Lu WW WW WW Lu Lu WR Re Fa NN OWN FA NY RK Fa FS BRR RFR RF Fa eR ITEM PART 37B 076053 39 13026 39 07142 39 13293 40 13027 40 07144 40 13294 4 13028 41 07146 4 13296 42 07173 42 07147 42 13297 42A 13298 43 13300 46 13302 46A 12055 46B 08059 46C 13304 46D 13306 46E 13307 46F 13308 46G 13309 47 13311 ATA 13312 47B 07700 471C 13314 47D 13306 ATE 13307 ATF 13308 48 13316 48A 07008 48B 07740 48C 07232 49 13362 32 13363 53 13358 54 13321 55 13322 DESCRIPTION O Ring GP5132 Pressure Ring GP5132 Pressure Ring GP5136 Pressure Ring GP5145 V Sleeve GP5132 V Sleeve GP5 136 V Sleeve GP5145 Sleeve Support Ring GP5132 Sleeve Support Ring GP5 136 Sleeve Support Ring GP5145 Tension Spring GP5132 Tension Spring GP5136 Tension Spring GP5145 Spring Guide GP5136 only Valve Casing Suction Valve Assy O Ring O Ring Suction Valve Seat Valve Plate Valve Spring Spring Tension Cap Spacer Pipe Discharge Valve Assy O Ring 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 PlugG 1 Plug G 1 1 2 o We WwW WwW WwW Ww oe UO SE JS bk bk bk E bk NO o e bech bh CO W UW Exploded View GP5100 Series Plunger Packing Kits GP5100 SERIES RE
8. PAIR KITS Valve Assembly Kits Inlet Valve Kit GP5100 Series 09231 Qty Part Description l 12055 O Ring l 08059 O Ring 1 13304 Valve Seat 1 13306 Valve Plate 1 13307 Valve Spring Discharge Valve Kit GP5100 Series 09232 Qty Part Description l 13312 O Ring H 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 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 Position ltem 24 13276 29C 07131 48A 07008 49 13362 Description Torque Amount ft Ibs Connecting Rod Assy 26 Tension Screw Plunger 26 Inner Hexagon Screw Plug 35 Inner Hexagon Screw Valve Casing 85 MALFUNCTION The Pressure and or the Delivery Drops Water in crankcase Noisy Operation Rough Pulsating Operation with Pressure Drop Pump Pressure as at gun Rated Pressure Excessive Leakage High Crankcase Temperature PUMPSYSTEM MALFUNCTION CAUSE Worn packing seals Broken valve spring Belt slippage Worn or Damaged nozzle Fouled discharge valve Fouled inlet strainer Worn or Damaged hose Worn or Plugged relief v
9. R A PARTICULAR PURPOSE AND ALL SUCH WARRANTIES ARE HEREBY DISCLAIMED AND EXCLUDED BY THE MANUFACTURER gt GIANT INDUSTRIES INC 900 N Westwood Ave P O Box 3187 Toledo Ohio 43607 Phone 419 531 4600 FAX 419 531 6836 www giantoumps com Copyright 1996 Giant Industries Inc 3 98 GP5100 PM6
10. Triplex Ceramic Plunger Pump Operating Instructions Manual Models GP5132 GP5136 amp 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 lubrica tion 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 us
11. alve on pump Cavitation pump for restrictions Unloader High humidity Worn seals Worn bearings Cavitation Worn packing Inlet restriction Accumulator pressure Unloader Cavitation and or proper size Restricted discharge plumbing Worn plungers Worn packing seals Excessive vacuum Cracked plungers Inlet pressure too high Wrong Grade of oil Improper amount of oil in crankcase 9 REMEDY Replace packing seals Replace spring Tighten or Replace belt Replace nozzle Clean valve assembly Clean strainer Repair Replace hose Clean Reset and Replace worn parts Check suction lines on inlet of Check for proper operation Reduce oil change interval Replace seals Replace bearings Refill crankcase oilwith recommended lubricant Check inlet lines for restrictions and or proper sizing Replace packing Check system for stoppage air leaks correctlysized inlet plumbing topump Recharge Replace accumulator Check for proper operation Check inlet lines for restrictions Re size discharge plumbing to Drop flowrate of pump Replace plungers Adjust or Replace packing seals Reduce suction vacuum Replace plungers Reduce inlet pressure Giant oil is recommended Adjust oil level to proper amount 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 non metal
12. e 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 IMPORTANT OPERATING CONDITIONS Failure to comply with any of these condi ons invalidates the warranty 1 Prior to initial operation add oil to crankcase so that ol 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 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 recom mended schedules Do not run the pump dry for extended periods of time
13. orse power 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 ITEM PART 1 13266 2 13000 3 07186 4 13267 5 13268 8 07105 9 01009 10 13270 11 13134 12 07703 13 13269 14 13271 15 13272 16 08182 17 13358 18 13134 20 13206 20A 13207 21 13273 22 13274 23 13275 24 13276 25 13279 28 13281 29A 07125 29B 13022 29B 07130 29B 13283 29C 07131 29D 07755 30 13282 31 13284 35 13359 35 13288 35 13287 35A 13289 35A 13286 35B 08183 36 13360 36 13291 36 13290 SE 13361 37A 07700 GP5100 Series PARTS LIST 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 G3 4 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 Crosshead Assy Crosshead Pin Centering Sleeve Plunger Pipe GP5 132 Plunger Pipe GP5 136 Plunger Pipe GP5145 Tension Screw Oil Scraper Copper Ring Radial Shaft Seal Seal Sleeve GP5 132 Seal Sleeve GP5 136 Seal Sleeve GP5145 O Ring GP5136 O Ring GP5145 O Ring Grooved Ring GP5 132 Grooved Ring GP5 136 Grooved Ring GP5145 Seal Case G
14. s are NOT covered or will void the warranty 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 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 FURTHERLOSS 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 FO
15. yond one or more of the limits specified above HORSEPOWER RATINGS GP5132 HORSEPOWER The rating shown are the power REQUIREMENTS requirements for the pump Gas GE PSI Pol E ES 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 horse power 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 GP5136 Kr ee ee ea es ere ee Up to 35 GPM ee EE Up to 2200 PSI SPC Oi uiassot anaes EERO OE AA AE AT AA O AEE A A AATE Up to 945 RPM le EE aa Up to 145 PSI Plein en REEL 36mm PIU GEES SUR OK EE 46mm Cratvkshalt Diameter E 35mm x 10mm key Ee EK S cecina Either side GHEET Top of pulley towards manifold Temperature of Pumped PGS EE Up to 140 F MU EE ere asics los susan sa EAEE IEO E TOAT 3 1 1 2 BSP Do Ee SOON ats cesar as oa nnaa eae crsasne ates eens meee 2 1 BSP Eeer 179 Ibs OE AC ASO e 1 2 Gal Floid End MCC e acta tesa ea da ealdte eeicainen tenaaned Seaatiaseaadeesdusade 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 REQUIREME
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