Giant P420A-5100 User's Manual
Contents
1. Inspect all parts for wear and replace as necessary Apply one drop of loctite 243 to the valve plugs 32 and tighten to 125 ft lbs 7 Remove the pressure rings 24 and v sleeves 23 and spacer ring 23A from the valve casing 26 Remove the remaining v sleeves 23B and pressure rings 24 from the seal case 20 Using needle nose pliers remove the inlet and dis charge valve assemblies 27A Note It may become neccesary to remove the valve seat 27 from the valve casing using a slidehammer Use a 8mm allen wrench to remove the 8 socket head cap screws 34 Carefully slide the valve casing 26 out over the plungers Re move the weep return rings 25 By inserting a small screw driver between the valve seat 27 and the valve spring re tainer 30 the valve assem bly can be separated Remove each seal case 20 with o rings and oil seals 21 and 22 from the crankcase 1 25 24 23 23A OO O00 O00 Note The orientation of oil seal in seal case is seal lips face crankcase 8 Inspect all parts for wear and replace as needed REASSEMBLY INSTRUCTIONS P420A 3100 5100 PUMPS 9 Check surfaces of plunger 10 Place each seal case 20 11 Place pressure rings and pipe 16B with new o rings 21 and weep seals 23B over 22 and new oil seals 19 plungers and into each seal over plungers 16 with case 20 weep hole down Gener ously lubricate o rings and oil seals before reas2. 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 whichthe 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 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 CONS
3. 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 785 900 P420A 3100 5100 HORSEPOWER RATINGS HORSEPOWER REQUIREMENTS The rating shown are the power 1500117001 2000 requirements for the pump Gas RPM Psi PSI engine power outputs must be 82196 approximately twice the pump 94 141 0 power requirements shown above 1010 10 5 12 4 1120 i 11 7 13 7 We recommend a 1 15 service factor 1240 Al 12 9 15 2 be specified when selecting an 1460 15 2 electric motor as the power source To compute specific pump horse power requirements use the following formula HP GPM X PSI 1450 SPECIAL NOTE The theoretical gallons per revolution gal rev is 0 0089 To find specific outputs at various RPM use the formula GPM 0 0089 x RPM ITEM PART P420A 3100 5100 PUMP PARTS LIST DESCRIPTION 1 2 3 3A 08377 08378 06479 07186 08380 12137 07182 08092 08093 08094 08471 08472 06245 01016 08095 07459 08473 08474 08475 08091 08390 07311 06611 08096 08398 07256 08097 07023 07203 Crankcase Oil Fill Plug with Gasket Crankcase cover Oil Sight Glass
4. 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 O Ring Screw with Washer Radial Shaft Seal Bearing Bearing Crankshaft Fitting Key Connecting Rod Assembly Screw with Washer Plunger Assy Items 16A 16G Plunger Base Plunger Pipe Centering Sleeve Tensioning Screwing O Ring Backup Ring QTY ITEM PART DESCRIPTION e e e e e a N WWW LULRUULURVOAUme emee ON Ree 16G 17 19 20 21 21 22 23 23A 23B 24 25 26 26 07161 0100 07314 08366 08098 06613 07266 08059 12254 08099 12255 08376 06373 06614 06374 06615 06375 06376 08371 06377 08372 07212 0001 07212 06616 06379 Copper Washer Crosshead Pin Oil Seal Seal Case O Ring P420 3 100 O Ring P420 5 100 O Ring V Sleeve Spacer Ring Weep Seal Pressure Ring Weep Return Ring Manifold P420 3100 Manifold P420 5100 Valve Assembly P420A 3100 Valve Assembly P420A 5 100 Valve Seat Valve Plate Valve Spring Valve Spring Retainer O Ring Viton P420A 3 100 O Ring P420A 5100 Plug P420A 3100 Plug P420A 5 100 07214 0100 O Ring Viton P420A 3100 07214 06612 13150 13321 0100 O Ring P420 5 100 Inner Hexagon Screw Plug G 3 4 P420 5100 Plug G 1 P420 5100 P420A 3100 5100 PUMP TORQUE SPECIFICATIONS RB RFK WOANTDATDAADAADAAAAAHDADHD KH KH WD WW ew WWW WW WwW WwW Position
5. EQUENTIAL 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 WAR RANTIES OR MERCHANTABILITY OR FITNESS FORAPARTICULAR 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 coneoA 3100 5100 PM6 Copyright 2001 Giant Industries Inc
6. Item 15A 07311 16D 08097 32 06616 06379 34 06612 Torque Amount 216 in lbs 240 in lbs 125 ft lbs 35 ft lbs Description Screw with Washer Tensioning Screw Plug P420 P422 Inner Hexegon Screw EXPLODED VIEW P420A 3100 5100 PUMPS P420 5100 only P420A 3100 5100 PUMP REPAIR KITS Plunger Packing Kits Oil Seal Kit 09542 P420 3100 09306 Item Part Description Oty Item Part Description Qty 3 3 21 06613 O Ring 19 08366 Oil Seal 3 22 08059 O Ring 23 12254 V Sleeve g Valve Assembly Kit P420A 3100 23B 12255 Weep Seal 09522 _ 24 08376 Pressure Ring Item Part Description 27A 06615 Valve Assembly Complete 33 07214 0100 O Ring Viton Plunger Packing Kits 09140 P420 5100 Item Part E Valve Assembly Kit P420A 5100 21 07266 O Ring 09478 22 08059 O Ring Item Part Description Qty 23 12254 V Sleeve 27A 06375 Valve Assembly Complete 6 33 07214 O Ring 6 23B 12255 Weep Seal 24 08376 Pressure Ring REPAIR INSTRUCTIONS P420A 3100 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 nonmetal parts i e the elastomers from cutting and scoring 1 With a socket wrench remove the three discharge valve plugs and three inlet valve plugs 32 Inspect the o ring 33 for wear and replace if damaged Remove the o ring 31
7. Triplex Ceramic O e S Plunger Pump Operating Instructions P420A 3100 amp P420A 5100 Corrossion Resistant Pumps Contents Installation Instructions page 2 Specifications page 3 Parts List Torque Specs page 4 Exploded View Kits page 5 Repair Instructions pages 6 7 Dimensions back page 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 inclination 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 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 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
8. ff 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 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 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 recommended 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 flow freely to the inlet of the pump Finally remember that high pressure operation ina pump system has many advantages But ifitis used carelessly and without regard to its potential hazard it can cause serious injury IMPORTANT OPERATING CONDITIONS Failure to comply with any of these conditions invalidates the warran
9. sembly 14 Slide valve casing over plungers and seat firmly Replace the 8 socket head cap screws 34 and tighten to 35 ft Ibs in a crossing pattern as shown below 12 Place weep return rings 25 13 Generously lubricate over the plunger 16 and v sleeves Assemble spacer pressure ring over plunger rings 23A and v sleeves 24 23 into valve casing 26 Contact Giant Industries or your local distributor for maintenance of the gear end of your pump Phone 419 531 4600 Contact Giant Industries for service school information Phone 419 531 4600 P420A 3100 5100 PUMP DIMENSIONS INCHES 2 x 3 4 BSPP 1 97 Discharge Connection enna un A Fe Serre a by de rer l i al 2 x 1 BSPP Suclion Connection 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 service 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 3 Six 6 months from the date of shipment for all rebuilt
10. ty 1 Prior to initial operation add oil to the crankcase so that oil level is between the two lines on the oil dipstick DO NOT OVERFILL Use Giant Oil 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 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 Specifications Model P420A 3100 5100 p to 13 0 GPM Discharge Pressure Jp to 2000 PSI at 11 GPM Inlet Pressure Jp to 140 PSI 4mm Jp to 1460 RPM Plunger Diameter 25mm Temperature of Pumped Fluids Jp to 160 F Inlet Ports 2 1 BSPP Discharge Ports 2 3 4 BSPP Shaft Rotation Top of pulley towards fluid end Mechanical Efficiency V4 GOs cceicsctevisesicedeesiuelerehastestelanscabtesienstiiodes 0 86 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
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