View Manual - Giant Pumps
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1. 07 09 Pump Model P450 5100 Corrosion Resistant Pump Triplex Ceramic Plunger Pump Operating Instructions Repair and Service Manual Contents Installation Instructions Specifications Exploded View Parts List Kits Repair Instructions Pump mounting selection Guide Recommended Spare Parts List Torque Specs Trouble Shooting Dimensions Warranty Information page 2 page 3 page 4 page 5 pages 6 8 page 9 page 9 page 9 page 10 page 11 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 installation If you have unique re quirements please contact Giant Indus tries 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 lubrication 2 The inlet to the pump should be sized for the flow rate of the pump with no unneces sary 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 160 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 to2. Cast Iron 2 gr AB Section Rails 07358 Plated Steel Channel Rails L 9 18 x W 1 88 x H 3 00 MALFUNCTION The Pressure and or the Delivery Drops Water in crankcase Noisy Operation Rough Pulsating Operation with sure Drop Pump Pressure as Rated Pressure Drop at gun Excessive Leakage High Crankcase Temperature PUMP SYSTEM 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 valve on pump Cavitation Unloader High humidity Worn seals Worn bearings Cavitation Worn packing Inlet restriction Accumulator pressure Unloader Cavitation 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 10 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 pump for restrictions Check for proper operation Reduce oil change interval Replace seals Replace bearings Refill crankcase oil with recommended lubricant Check inlet lines for restrictions and or proper sizing Replace packing Check system for stoppage air Pres leaks correctly sized inlet
3. We recommend a 1 15 service factor be specified when selecting an electric motor as the power source To compute specific pump SPECIAL NOTE horsepower requirements use the following formula The theoretical gallons per revolution gal rev is 0 00379 HP GPM X PSI 1450 To find specific outputs at various RPM use the formula GPM 0 00379 x RPM P450 5100 Exploded View ITEM PART 1 08377 2 08378 3 06479 3A 07186 4 08380 5 07109 0400 5A 07182 5B 08092 0100 6 01010 0100 6A 01011 0400 05290 8 05291 8A 05292 8B 05293 9 01016 10 07114 0100 11 07459 1 05350 13 08482 14 08091 15 08390 15B 05349 15C 05346 16 05575 16A 08384 0600 16B 08397 P450 5100 Parts List DESCRIPTION Crankcase Oil Fill Plug with Gasket Crankcase cover Oil Sight Glass w Gasket O Ring Oil Drain Plug Gasket for Oil Drain Plug Plug with Gasket Screw Spring Washer Bearing Cover Open Bearing Cover Closed Shim Shim May not be present O Ring Screw with Washer Radial Shaft Seal Bearing Crankshaft Fitting Key Connecting Rod Assembly Screw Washer Plunger Assy Items 16A 16G Plunger Base Plunger Pipe QTY a a a a ck ek U 9 Na ONA ana ITEM 16D 16E 16F 16G 16H 17 19 20 21 23 24 25 26 2 28 29 30 31 32 33 34 36 36A 36B 36C PART 08399 0100 07023 0001
4. 07203 07161 0100 06931 06790 05444 05534 0100 07266 08477 07929 06804 08470 5000 05578 05576 05577 07906 0100 07907 07770 0001 08406 0100 07489 08396 0100 12250 06807 13150 0100 06808 P450 5100 Repair Kits Plunger Packing Kits 09141 Item Part 21 07266 23 08477 24 07929 Description Qty O Ring 3 V Sleeve 18mm 6 3 Pressure Ring DESCRIPTION Tensioning Screw O Ring Backup Ring Copper Washer Oil Scraper Crosshead Pin Oil Seal Seal Case O Ring V Sleeve 18mm Pressure Ring Weep Return Ring Manifold Valve Assembly Valve Seat Valve Plate Valve Spring Valve Spring Retainer O Ring Plug O Ring Cap Screw Plug 1 2 BSP Steel Ring Plug 3 4 S S Steel Seal Ring Oil Seal Kit 09641 Item Part Description Qty 19 05444 Oil Seal 3 Valve Assembly Kit 09646 Item Part Description Qty 27A 05578 Valve Ass y Complete 6 33 07469 O Ring 6 lt Repair Instructions P450 5100 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 nonmetal parts i e the elastomers from cutting and scoring 1 With a socket wrench 2 Using needle nose pli 3 By inserting a small screw remove the three dis charge valve plugs and three inlet va
5. Ports cccccccsccceeccseeceecceeceeecaeeceeceeecaeecueecueesseeseeeeaes 2 1 2 BSP ohant Fs 1 9 9 95 5 anani a Top of pulley towards fluid end Crankshaft DiaMmetel ccccccccecccsseeceeeceeeeceseeseceseeeeseeeesaeesaeeeees 28mm VIN cea ee ees ce aces EE EEEE E E 8mm Shaft WMOUMTING sc cesses ier 88 8 Either side ALE g AEE E E E E PENE DO ODS aenn 16 6 kg Crankcase 8 861 SONOZ srs ri 0 89 liters 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 NOTES In order to drive the pump from the side opposite the present shaft extension simply remove the valve casing from the crankcase and rotate the pumps 180 degrees to the desired position Be certain to rotate the seal case item 20 as well so that the weep holes are down at the six o clock position Exchange the oil fill and the oil drain plugs also Refer to the repair instructions as necessary for the proper assembly sequence P450 5100 HORSEPOWER RATINGS HORSEPOWER REQUIREMENTS The rating shown are the power RPM GPM 2000 PSI 3000 PSI 4000 PSI 5000 PSI requirements for the pump Gas en gine power outputs must be approxi mately twice the pump power requirements shown above
6. 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 off gun 4 Use of a dampener is necessary to mini mize pulsation at drive elements plumbing connections and other system areas The use of a dampener with Giant Industries Inc pumps is optional although recom mended 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 5 Crankshaft rotation on Giant Industries Inc pumps should be made in the direc tion designated by the arrows on the pump crankcase Reverse rotation may be safely achieved by following a few guidelines avail able upon request from Giant Industries Inc Required horsepower for system operation can be obtained from the chart on page 3 6 Before beginning operation of your pump ing system remember Check that the crankcase and seal areas have been properly lubricated per recommended sched ules 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 flow freely to the inlet of the pump IMPORTANT OPERATING CONDITIONS Failure to comply with any of these conditions invalidates the warranty 1 Prior to i
7. LY 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 WAR RANTIES 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 Toledo Ohio 43607 PHONE 419 531 4600 FAX 419 531 6836 www giantpumps com Copyright 2009 Giant Industries Inc 07 09 P450 5100 indd
8. d halves on crankshaft matching them with other half and tighten screws 15 to 97 Ib in 11 Nm Replace crankcase cover 3 and o ring 4 When remounting the valve casing 26 tighten hexagon socket screws 34 to 29 5 5 40 Nm To Move Crankshaft to Opposite Side Remove the valve casing 26 and seal case 20 Then rotate the crankcase 180 Interchange the oil plug 5B with oil dipstick 2 Rotate the crankcase cover 3 180 Remount the valve casing together with the seal casing and the seal adapters 20 Make sure that the seal adapters are rotated in order that the bores face downwards Preventative Maintenance Check List amp Recommended Spare Parts List Every Every Every Dally Weekly 20 PTS 200 hrs 1500 hrs 3000 hrs Oil Level Quality Oil Leaks Water Leaks Belts Pulley Recommended Spare Parts oichangepinorisa x TTT Tet see page 5 for kit list eme J see page 5 for kit list Valve Spare Parts 1 kit pump a see page 5 for kit list P450 5100 PUMP TORQUE SPECIFICATIONS Position ltem Description Torque Amount 15A N A Screw with Washer 97 in lbs 11 Nm 16D 08399 0100 Tensioning Screw 221 to 265 in lbs 25 30 Nm 32 08406 0100 Plug 125 ft lbs 170 Nm 34 08396 0100 Inner Hexagon Screw 29 5 ft lbs 40 Nm Pump Mounting Selection Guide Bushings 07175 28 mm Tapered H Bushing Pulley amp Sheaves 01055 7 75 Cast Iron 2 gr AB Section 01062 7 75
9. ipment 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 o n w N 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 work manship 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 war ranty 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 DIRECT
10. kcase cover 3 Remove valve casing 26 and seal case 20 Then remove plunger pipes 16B and oil scrapers 16H as described above IMPORTANT Before removing conn rods be aware of their position on the crankshaft so as to return them to the same location when re assembling Remove screws from connecting rods 15 separate the back conn rod half from the crankshaft and the front conn rod half The conn rod halves must be kept as pairs do not mix them up Push conn rod shaft as far as possible into the crosshead guide Remove screws 10 and pry bearing covers 7 8 off gently with a screwdriver Carefully remove crankshaft 13 by threading it through the conn rods 15 making sure not to bend the conn rods Remove and disassemble conn rods and plungers 16 paying close attention not to damage the plungers Pry out oil seal 19 using a screwdriver Examine plunger surfaces 16A and replace if necessary To re assemble first press the oil seal 19 into the crankcase Then insert conn rods with plungers remembering their original location Thread in the crankshaft 13 Replace bearing cover 7 and O ring 9 together with the radial shaft seal 11 and roller bearing 12 and fix in place with screws 10 Replace roller bearing 12 bearing cover 8 and O ring 9 Adjust the clearance by fitting shims 8A under the bearing cover as required to ensure that the crankshaft 13 turns easily without play being felt Finally mount conn ro
11. lve plugs 32 Inspect the o ring 33 for wear and replace if damaged ers remove the inlet and discharge valve assem blies 27A Note It may become neccesary to remove the valve seat 27 from the valve casing using a slidehammer driver between the valve seat 27 and the valve Spring retainer 30 the valve assembly can be separated 4 Remove the O ring 31 Inspect all parts for wear and replace as necessary Apply one drop of loctite 243 to the valve plugs 32 and tighten to 125 Ib ft 170 Nm 7 Remove the pressure rings 24 and v sleeves 23 from the valve cas ing 26 5 Use a 8mm allen wrench to remove the 8 socket head cap screws 34 Carefully slide the valve casing 26 out over the plungers 8 Remove the weep grooved seal 23 out of the seal adaptor 20 Check O rings 21 6 Remove seal adaptors 20 and weep return rings 25 from the valve casing IMPORTANT The grooved seal 23 on the high pressure side is to be fitted carefully into the valve casing 26 using a screwdriver Under no circum stances must the seal surface in the valve casing or the seal lip be damaged REASSEMBLY INSTRUCTIONS P450 5100 9 Check surfaces of plunger 16 Damaged surfaces cause accelerated seal wear Deposits of all kinds must be removed from the plungers IMPORTANT Plunger surfaces are not to be damaged If there are lime deposits in the pump care must be
12. nitial operation add oil to the crank case so that oil level is between the two lines on the oil dipstick DO NOT OVERFILL Use Giant Oil 01154 or the equivalent SAE 80W 90 Industrial Gear oil Crankcase oil should be changed after the first 50 hours of operation then at regular inter vals of 500 hours or less depending on operating conditions 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 can not 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 Model P450 5100 Specifications U S Metric 11 1111 etesnisarnecaremenaie caeonneneeh 5 5 GPM 20 8 m Discharge Pressure ccssccseeeseeeeeees 9079 PSl 350 bar Inlet PrESSULE ccceccceeeceeeceeeceeeeeeeaees 1 1 6 2 bar VOKE caer ance ee a E E OES E EE een 20mm S E E E E E E EE A Up to 1450 RPM Plunger 122116 OTT meer erent erie enter ee 18mm Temperature of Pumped Fluids UG OPE 70 C gS A a 9 ae nee eee ee Pe ee Coe ec eee ee 2 3 4 BSP Discharge
13. plumbing to pump Recharge Replace accumulator Check for proper operation Check inlet lines for restrictions and or proper size Re size discharge plumbing to flow rate 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 3 5 89 _ 2 6 67 P450 5100 Pump Dimensions Inches mm 1111 8x7x45 Fitting Key DN oO 83 21 2 5 _ 5 3 135 distance between feet 4 1 6 0 103 453 5 a 3 1 78 5 7 4 188 o 6 8 173 5 Discharge 2x 1 2 BSP 2110 2 x 3 4 BSP 81 64 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 self serve 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 carwash 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 sh
14. taken that the drip return bore in parts 25 and 26 ensure trouble free 10 If the plunger pipe 16B or oil seal 19 is worn re move tension screw 16D and remove along with plunger pipe 16B Check and clean plunger surface 16A check oil scraper 16H Remove the seal case 20 and if necessary replace oil seals with seal lips facing crankcase 1 Cover thread of tension screw 16D with a thin film of Loctite and tighten carefully to 221 265 in lbs IMPORTANT Care must be taken that glue does not get between the plunger pipe 16B and plunger base 16A The plunger pipe should not be strained by eccentric tightening of the tension screw or through damage to front surface of plunger otherwise it is liable to fracture drip return 25 30NM 11 After installation of high pressure seals 23 place seal adapter 20 with weep seals amp pressure ring installed weep return ring 25 and high pressure weep return ring 24 over plungers Slide valve casing over plungers and seat firm ly Replace the 8 socket head cap screws 34 and tighten to 29 5 40 Nm in a crossing pattern as shown on the right Contact Giant Industries for service school information Phone 419 531 4600 Gear End If oil leaks where the plunger 16 extends from the crankcase 1 the oil seals 19 and plungers 16 must be examined and replaced if necessary Remove oil plug 5 and drain oil remove cran
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