Giant GP5132HS Instruction Manual

Contents:
Installation Instructions: page 2
Pump Specications: page 3
Exploded View: page 4
Parts List: page 5
Kits/Torque Specs: page 5
Repair Instructions: page 6
Dimensions: page 7
Warranty Information back page
Model
GP5132HS
Triplex Ceramic
Plunger Pump
Operating Instructions /
Manual
Hydraulic Drive Pump

2
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.
INSTALLATION INSTRUCTIONS
IMPORTANT OPERATING CONDITIONS
Failure to comply with any of these
conditions invalidates the warranty
1. Prior to initial operation, add oil to crankcase so
that oil level is between the two lines on the oil dip-
stick. DO NOT OVERFILL.
SAE 80 or SAE 90 Industrial
Gear Oil may be used. (Giant p/n 01154)
Caution! When operating in damp places or with high
temperature uctuations, the oil must be changed im-
mediately should condensate (frothy oil) occur in the
gear box.Crankcase oil should be changed after the
rst 50 hours of operation, then at regular intervals of
500 hours or less depending on operating conditions.
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 out-
line for installation. If you have unique require-
ments, please contact Giant Industries, Inc. or
your local distributor for assistance.
1. The pump should be installed at on a base to a
maximum of a 15 degree angle of inclination to en-
sure optimum lubrication.
2. The inlet to the pump should be sized for the ow
rate of the pump with no unnecessary restrictions that
can cause cavitation. Teon tape should be used to
seal all joints. If pumps are to be operated at temper-
atures in excess of 1400F, it is important to insure a
positive head to the pump to prevent cavitation. Keep
NPSH must be observed. Make sure that suction
pulsation is su󰀩ciently dampened - water column
resonance must be avoided.
3. The discharge plumbing from the pump should be
properly sized to the ow rate to prevent line pres-
sure 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 use of a shut-o󰀨 gun.
4. Use of a dampener is necessary to minimize pul-
sation 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-o󰀨 gun. A
dampener must be positioned downstream from the
unloader.
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 Indus-
tries, Inc. Required horsepower for system opera-
tion can be obtained from the chart on page 3.
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. Cavitation will result in
severe damage. Always remember to check that all
plumbing valves are open and that pumped media
can ow freely to the inlet of the pump.
Important! If there is a danger of frost, the wa-
ter in the pump and in the pump ttings (particularly
the unloader valve) must be emptied. The second
discharge port can also be used and the pump run
“dry” for 1-2 minutes for this purpose.
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 uids 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 tem-
peratures.

3
U.S........................... (Metric)
Volume.......................................................... 27.7 GPM .............. 104.9 LPM
Discharge Pressure......................................2900 PSI ................. 200 bar
Speed (Continuous)...................................... ................................ 1000 RPM
Inlet Pressure (maximum) ............................-4.35 to145 PSI ...... -0.3 to 10 bar
Plunger Diameter..........................................1.26” ........................ 32 mm
Crankshft Stroke...........................................1.81” ........................ 46 mm
Crankshaft Bore............................................................................. SAE C Flange C32 Shaft (ø31,75)
Crankshaft Mounting ..................................................................... Either side
Shaft Rotation................................................................................ Towards manifold
Temperature of Pumped Fluids ....................Up to 140oF ............. (60oC)
Inlet Ports ...................................................................................... (3) 1-1/2” NPT
Discharge Ports............................................................................. (2) 1” NPT
Weight ..........................................................179 lbs. ................... (81 kg)
Crankcase Oil Capacity................................1.2 Gal. ................... (4.6 liter)
Fluid End Material......................................... ................................ Nickel-Plated Spheroidical Cast Iron
Specications
Model GP5132HS
Consult the factory for special requirements that must be met if the pump is to
operate beyond one or more of the limits specied above.
PULLEY INFORMATION
Pulley selection and pump speed are based on
a 1725 RPM motor and “B” section belts. When
selecting desired GPM, allow for a ±5% tolerance
on pumps output due to variations in pulleys, belts
and motors among manufacturers.
1. Select GPM required, then select appropriate
motor and pump pulley from the same line.
2. The desired pressure is achieved by selecting
the correct nozzle size that corresponds with the
pump GPM.
HORSEPOWER INFORMATION
Horsepower ratings 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 that a 1.15 service factor be speci-
ed when selecting an electric motor as the power
source. To compute specic pump horsepower
requirements, use the following formula:
(GPM X PSI) / 1450 = HP
For the Application of a Hydraulic Motor:
To Determine the Torque of a Hydraulic Motor -- (GPM x PSI x 36.77) / RPM = Torque (in-lbs)
Position Item# Description Torque Amount - Ft.-lbs (NM)
24 13276 Connecting Rod Assy. 26 (35NM)
29C 13031 Tension Screw, Plunger 26 (35NM)
48A 07008 Inner Hexagon Screw, Plug 35 (47)
49 13339 Inner Hexagon Screw, Valve Casing 74-89 (100-120)
GP5132HS Torque Specications

4
GP5132HS Exploded View

5
ITEM PART DESCRIPTION QTY.
1 13266 Crankcase 1
2 13000 Oil Filler Plug Assembly 1
3 05943 Oil Sight Glass Assy. 1
4 13267 Crankcase Cover 1
5 13268 O-Ring 1
8 07105 Oil Dip Stick 1
9 01009 O-Ring, Dip Stick 1
10 07008 Inner Hexagon Screw 4
11 06725 Spring Washer 4
12 07703 Drain Plug 3/4” BSP 1
13 07704 Gasket, Drain Plug 1
14 13271 Bearing Cover 1
14A 04467 Bearing Cover 1
15 05771 Radial Shaft Seal 1
15A 08439 Lid 1
16 08182 O-Ring 2
17 13358 Hexagon Screw 4
17A 07008 Hexagon Socket Screw 4
18 06725 Spring Washer 4
20 13206 Taper Roller Bearing 1
20A 13207 Fitting Disc (Shim), 0.1 mm 1-2
20B 04723* Fitting Disc (Shim), 0.15 mm 1-2
20C 04724* Fitting Disc (Shim), 0.2 mm 1-2
21 04468 Tapered Roller Bearing 1
22 04469 Crankshaft 1
24 13276 Connecting Rod Assy. 3
25 13279 Crosshead Assy. 3
28 13281 Crosshead Pin 3
29A 07125 Centering Sleeve 3
29B 13022 Plunger Pipe 3
29C 13031 Tensioning Screw 3
29D 07755 Copper Ring 3
30 13282 Oil Scraper 3
30A 05889 Washer for Drip Shield 3
31 13284 Radial Shaft Seal 3
*May not be present
GP5132HS Spare Parts List
ITEM PART DESCRIPTION QTY.
35 13359 Seal Sleeve 3
35B 08183 O-Ring 3
36 13360 Grooved Ring 3
37 13361 Seal Case 3
37A 07700 O-Ring 3
37B 07653 O-Ring 3
39 13026 Pressure Ring 3
40 13027 V-Sleeve 6
41 13028 Sleeve Support Ring 3
42 07173 Tension Spring 3
43 13300 Valve Casing 1
44 07109 Plug, 1/2” BSP 1
45 06272 Copper Washer 1/2” 1
46 13302 Inlet Valve Assembly 3
46A 12055 O-Ring 3
46B 08059 O-Ring 3
46C 13304 Valve Seat 3
46D 13306 Valve Plate 3
46E 13307 Valve Spring 3
46F 13308 Spring Tension Cap 3
46G 13309 Spacer Pipe 3
47 13311 Discharge Valve Assembly 3
47A 13289 O-Ring 3
47B 07700 O-Ring 3
47C 13314 Discharge Valve Seat 3
47D 13306 Valve Plate 3
47E 13307 Valve Spring 3
47F 13308 Spring Tension Cap 3
48 13316 Plug 3
48A 07008 Inner Hexagon Screw 12
48B 07740 O-Ring 3
48C 07232 Tension Spring 3
49 13339 Inner Hexagon Screw 8
56 07623 Eye Bolt 1
56A 22610 Plug, 1/4” NPT 3
GP5132HS Repair Kits
Plunger Packing Kit - #09290
Item Part# Description Qty.
35B 08183 O-Ring 3
36 13260 Grooved Ring 3
40 13027 V-Sleeve 6
Inlet Valve Kit - #09231
Item Part# Description Qty.
46A 12055 O-Ring 1
46B 08059 O-Ring 1
46C 13304 Valve Seat 1
46D 13306 Valve Plate 1
46E 13307 Valve Spring 1
Discharge Valve Kit - #09232
Item Part # Description Qty.
47A 13289 O-Ring 1
47B 07700 O-Ring 1
47C 13314 Valve Seat 1
47D 13306 Valve Plate 1
47E 13307 Valve Spring 1
Oil Seal Kit - #09230
Item Part # Description Qty.
31 13284 Oil Seal 3

6
To Check Valves
Remove inner hexagon screw (48A) and remove plugs (48) with a screwdriver. Check O-rings on plugs (48B).
Pull out tension spring (48C). Take spacer pipe (46D) together with the discharge valve out of the valve casing
using a clipring pliers or a ø22 extractor tool. Remove the next exposed spacer pipe and suction valve as already
described. Remove the valve seats (46A) from the spacer pipes by lightly tapping the valve plate (46B) from
above with a plastic rod. Check sealing surfaces and replace worn parts.
When reassembling, use new O-rings if possible and oil them before installing.
Tighten inner hexagon screws (48A) to 35 Ft-Lbs (47NM).
To Check Seals and Plunger Pipe
Loosen the 8 nut and pull o󰀨 valve casing to the front. Pull seal sleeves (35) out of guides in crankcase and over
the plunger pipe (29B). Pull support ring (41), sleeves (40) and pressure ring (39) out of seal sleeve.
Check plunger surfaces, sleeves (40) and grooved rings (36). Replace worn parts.
If the plunger pipe is worn out, loosen tension screw (29C) and pull o󰀨 plunger pipe to the front. Clean contact
surfaces of plunger (25) thoroughly. Then place new plunger pipe carefully through the oiled seals into the seal
case. Check O-rings (35A, 35B) on seal sleeves and replace worn O-rings. Then push seal sleeve together with
plunger pipe into the crankcase guide. Turn gear carefully until plunger (25) comes up against the plunger pipe.
Put a new copper gasket (29D) onto the tension screw (29C). Cover the thread of tension screw and the gasket
with glue and tighten to 26 Ft.-lbs. (35NM).
Important! Care must be taken that no glue gets between the plunger pipe (29B) and the centering sleeve
(29A). The plunger pipe should not be strained by eccentric tightening of the tension screw or through damage
to front of surface of plunger, otherwise it will probably break. Tighten the inner screws (49) for the valve casing
evenly to 74-89 Ft.-Lbs. (100-120NM).
To Dismantle Drive
Drain oil after dismantling the valve casing and plunger pipes. Screw o󰀨 crankcase cover (4) and bearing cover
(14, 14A). Remove connecting rod screws (24), push the front connecting rod parts as far as possible into the
crosshead guide and carefully push out the radial shaft seals (31).
Important! Do not twist connecting rod halves. The connecting rods are marked for identication and must be
remounted onto the shaft journals in the exact original position.
Turn the crankshaft lightly and hit it out preferably in the direction of the hollow shaft bore using a rubber
hammer.
Important! Do not bend connecting rod shanks. Examine the surfaces of the crankshaft, connecting rods,
crossheads and plungers (25) as well as radial shaft seals (15, 31) and taper roller bearings (20).
To Reassemble
Using a soft tool, press in the outer bearing ring (20) on the non-drive side until it lines up with the outer edge
of the bearing hole. Then t bearing cover (14) together with cap plug (15A) and o-ring (16). Insert shaft with
pressed-on bearing parts through the bearing hole on the opposite side. Press in the outer bearing ring (21)
and x this with the bearing cover, keeping the shaft in a vertical position and turning it slowly so that the taper
rollers of the bearings lie at with the outer bearing ring. Check axial bearing clearance and if necessary adjust
by placing shims 0.1mm (20A) under (14) and (14A). The shaft should turn easily with very little clearance.
Tighten hexagon socket screws on connecting rod (24) to 22 ft.-lbs. (30 Nm).
Important! A little clearance must exist to enable slight sideward movement of the connecting rod on its
journal.
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
to the right).
GP5132HS Repair Instructions

7
GP5132HS Dimensions Inches (mm)

GIANT INDUSTRIES, INC.,
900 N. Westwood Ave., Toledo, Ohio 43607
Phone [phone], FAX [phone],
www.giantpumps.com
© Copyright 2016 Giant Industries, Inc. 12/16 GP5132HS.indd
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. Five (5) years from the date of shipment for all pumps used in portable pressure
washers with NON-SALINE, clean water applications.
2. Two (2) years from the date of shipment for Giant pumps used in car wash
applications.
3. One (1) year from the date of shipment for all other Giant industrial and consumer
pumps.
4. Six (6) months from the date of shipment for all rebuilt pumps
5. 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 modications made by the customer or third party.
6. The operation of pumps and or accessories exceeding the specications 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 [phone] 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 WARRANTIES OR MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE AND ALL SUCH WARRANTIES ARE HEREBY DISCLAIMED AND
EXCLUDED BY THE MANUFACTURER.
WARNING: This product might contain a chemical known to the State of California to
cause cancer, and birth defects or other reproductive harm.
For more information go to www.P65Warnings.ca.gov