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
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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
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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
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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
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Exploded View - GP5136-5100 and GP5145-5100 Pumps
6
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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
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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
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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
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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
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Pump Dimensions - GP5136-5100 and GP5145-5100 Pumps - Inches (mm)
11
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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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