Giant P46HT User's Manual
Contents
1. BISCLAIMED ANB BEDS 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 com Copyright 1998 Giant Industries Inc 3 98 P46HT PM62. 194 F to 220 F Up to 220 2 1 2 BSP 2 3 8 BSP Either Side Top of pulley towards Head 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 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 require ments for the pump Gas engine power outputs must be approximately twice the pump power requirements shown above We recommend that a 1 1 service factor be specified when selecting an electric motor as the power source To compute specific pump horsepower requirements use the following formula GPH X PSD 87 375 HP P46HT PULLEY SELECTION AND HORSEPOWER REQUIREMENTS opm rem putty PULY soo psi zoss soo psi PULLY PULLY 700 PSI 900 PSI a fon re a0 oa sr fon oe I me ars 3 2 as osa 100 1GPH Gallons per hour INSTALLATION INSTRUCTIONS Installation of the Giant Industries Inc pump is not a complicated procedure but there are some basic steps common to all pum
3. 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 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 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 in a pump system has many advah tages 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 instal
4. Plug Outlet 32 ft Ibs P46HT PARTS LIST PART DESCRIPTION 07222 Crankcase 07181 Vent Filler Plug with Seal 08004 Cover Crankcase 08005 O Ring 08008 Oil Dipstick 01009 O Ring 07188 Cylinder Screw with Slot 07223 Spring Washer 08012 Oil Drain Plug with Seal 08013 Gasket 07245 Bearing Cover 08015 Radial Shaft Seal 08020 Grooved Ball Bearing 07225 Hexagon Screw 07226 Shaft Protector 08022 Crankshaft 01024 Woodruff Key 08024 Connecting Rod 07201 Crosshead Assy 01031 Crosshead Pin 07021 Plunger Pipe 08456 Tension Screw 08457 Copper Screw 13333 Oil Scraper 07206 Radial Shaft Seal 11510 Spacer Sleeve 07207 Centering Sleeve 07033 Valve Casing 11502 Stud Bolt 07230 Pressure Ring 11511 Sleeve 07231 Support Ring 07232 Pressure Spring 06018 0100 Spring Tension Cap 06017 0100 Valve Spring 06016 Valve Plate 06014 Valve Seat 06015 O Ring 07233 Suction Valve Adaptor 07234 O Ring 07235 Plug 12004 O Ring 07792 Plug 07035 O Ring 07215 Stud Bolt 08040 Hex Nut 08041 Disc 07237 Intermediate Casing 07238 O Ring 11512 Sleeve 07240 Support Ring 07109 Plug 13338 Plug KRU R RE RE EEE AAA THEE NE Eee ee l Model P46HT TRIPLEX CERAMIC PLUNGER PUMP Volume Discharge Pressure Inlet Pressure Plunger Diameter Crankcase Capacity Temperature Inlet Ports Discharge Ports Pulley Mounting Shaft Rotation Weight Up to 127 GPH 900 PSI 6 PSI minimum 194 F 15 PSI min
5. Triplex Ceramic Plunger Pump Operating Instructions Repair and Service Manual Contents Installation Instructions page 2 Pump Specifications page 3 Exploded View page 4 Kits Torque Specs page 4 Parts List page 5 Trouble Shooting page 6 Repair Instructions page 7 Dimensions back page Warranty Information back page Updated 3 98 REPAIR INSTRUCTIONS P46HT To Check Suction and Discharge Valves Loosen valve plugs 41 and 43 using a socket wrench Note the arrangement for reassembly and check the discharge valves underneath and suction valves in suction valve adapter 39 To Check V Sleeves Separate valve casing 29 from the crankcase 1 and pull off over the plungers If the seals have to be replaced remove all parts from the valve casing 29 in the suction valve direction Grease new v sleeves 31 with grease before installing Examine the surfaces of the plunger pipes 24A as damaged surfaces cause the seals to wear out quickly To Check Plungers and Crankcase If oil leaks at plunger outlet 22 and or the radial shaft seal 26 the worn plungers and crosshead plunger assembly must be placed Drain oil and remove crank case cover 3 and valve casing 29 Take off bearing cover 12 and shaft protec tor 17 on one side before removing the crankshaft 18 Then remove crankshaft axially by means of a press or a rubber hammer Do not force the cranks on the shaft when pulling through the connecting r
6. led 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 Information Phone 419 531 4600 P46HT DIMENSIONS INCHES 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 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 wi
7. ll 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 O Y OR FITNESS FOR A PARTICULAR PURPOSE AND ALL SUCH A
8. od 20 Do not bend connecting rod Dismantle crosshead and connecting rod and replace worn parts Reinstall the crankshaftfirst being particularly careful with the cranks Then press on the bearing on both sides and finally install radial shaft seal and bearing cover To Replace Plunger Pipes Screw out tension screw 24B pull off plunger pipes 24A and clean plunger surface Install new plunger pipe Fix tension screwwith screw glue and tighten carefully at 106ft Ibs Drip Return After the valve casing has been removed the weep seals 50 in the intermediate casing 46 can be examined and replaced as necessary Should lime deposits occur in the valve casing care must be taken in keeping the two holes in the valve casing 29 free to ensure trouble free drip return NOTE Contact Giant Industries for Service School Information Phone 419 531 4600 MALFUNCTION The Pressure and or the Delivery Drops Waterincrankcase Noisy Operation Rough Pulsating Operation with Pressure Drop Pressure Drop at Gun Excessive Leakage High Crankcase Temperature PUMP SYSTEM MALFUNCTION CAUSE Worn packing seals Broken valve spring Belt shppage Worn or Damagednozzle Fouled discharge valve Fouledinlet strainer Worn or Damaged hose Wor or Pluggedreliefvalve on pump Cavitation Unloader Highhumidity Wornseals Worn bearings Cavitation Wor packing Inlet restriction Accumulator pressure Unloader Ca
9. ps 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 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 220 F it is important to insure a positive head to the pump to prevent cavita tion See chart below 3 The discharge plumbing from the pump should be properly sized to the flow 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 off NPSHR FT HEAD 400 60 IMPORTANT OPERATING CONDITIONS Failure to comply with any of these conditions invalidates the warranty 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 Industrial Grade 90 wt 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 gun
10. vitation Restricted discharge plumbing Worm plungers Worm packing seals Excessive vacuum Cracked plungers Inlet pressure too high Wrong Grade of oil Improper amount of oil in crankcase REMEDY Replace packing seals Replace spring Tighten or Replace belt Replace nozzle Clean valve assembly Clean strainer Repair Replace hose Clean Reset andReplace wom parts Check suction lines oninlet of pump forrestrictions Check for proper operation Reduce oil change interval Replace seals Replace bearings Refill crankcase oil withrecommendedlubnicant Checkinlet lines for restrictions and or proper sizing Replace packing Check system for stoppage air leaks correctly sizedinlet plumbing topump Recharge Replace accumulator Check for proper operation Check inlet lines for restrictions and or proper size Re size discharge plumbing to flowrate of pump Replace plungers Adjust or Replace packing seals Reduce suctionvacuum Replace plungers Reduceinlet pressure Giant oil is recommended Adjust oil level to proper amount Exploded View P46HT P46HT REPAIR KITS Valve Kit 09458 Seal Kit 09514 Part Description Qty Part Description 06018 0100 Valve Cage 3 11510 Spacer Sleeve 06017 0100 Valve Spring 3 11511 Sleeve 06016 Valve Plate 06014 Valve Seat 06015 O Ring P46HT TORQUE SPECIFICATIONS Position Description Torque Amount 24B Tension Screw Plunger 108 in Ibs 41 Plug Inlet 33 37 f Ibs 43
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