Giant P420A-3100 User's Manual
Contents
1. Remove each seal case 20 with o rings and oil seals 21 and 22 from the crankcase 1 21 24 23 B 25 24 23 23A 008 O00 000 Note The orientation of oil seal in seal case is seal lips face crankcase 7 Remove the pressure rings 8 Inspect all parts for wear and replace as needed 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 REASSEMBLY INSTRUCTIONS P420A 3100 3100 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 reassembly 14 Slide valve casing over plungers and seat firmly Replace the 8 socket head cap screws 34 and tighten to 35 ft lbs 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 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 Cast Iron 2 gr AB Section Rails 07358 Plated Steel Channel Rails L 92. Viton P420A 3100 16C 07256 Centering Sleeve 3 33 07214 O Ring P420 5100 16D 08097 Tensioning Screwing 3 34 06612 Inner Hexagon Screw 16E 07023 O Ring 3 36 13150 Plug G 3 4 P420 5100 16F 07203 Backup Ring 3 37 13321 0100 Plug G 1 P420 5100 P420A 3100 5100 PUMP TORQUE SPECIFICATIONS Position ltem Description Torque Amount ISA 07311 Screw with Washer 216 in lbs 16D 08097 Tensioning Screw 240 in lbs 32 06616 06379 Plug P420A 3100 P420A 5100 125 ft lbs 34 06612 Inner Hexegon Screw 35 ft lbs Preventative Maintenance Check List amp Recommended Spare Parts List Check EI Oil Level Quality Oil Leaks Water Leaks Belts Pulley Plumbing Oil Change Seal Spare Parts 1 kit pump See page 5 for kit list Oil Seal Kit 1 kit pump See page 5 for kit lit Valve Spare Parts 1 kit pump See page 5 for kit list Weekly Every 500 hrs Every 1500 hrs Every 3000 hrs H aaararaaaaraHvaveuvuowewub EXPLODED VIEW P420A 3100 3100 PUMPS Item 36 amp 37 P420 5100 only P420A 3100 5100 PUMP REPAIR KITS Plunger Packing Kits Oil Seal Kit 09542 P420 3100 09306 Item Part Description Qty Item ban Description Qty 21 06613 O Ring 3 19 08366 Oil Seal 3 22 08059 O Ring 3 23 12254 V Sleeve 3 i Valve Assembly Kit P420A 3100 23B 12255 Weep Seal 3 09522 E 24 08376 PressureRing 6 Item Part Description Qty 27A 06615 Valve Assembly Complete 6 33 07214 0001 O Ring Vit
3. 1120 99 69 10 3 11 7 13 7_ 7 75 775 11460 13 0 89 1134 15 2 P420A 3100 5100 PUMP PARTS LIST ITEM PART DESCRIPTION OTY ITEM PART DESCRIPTION 1 08377 Crankcase 1 16G 07161 0100 Copper Washer 2 08378 Oil Fill Plug with Gasket 1 17 07314 Crosshead Pin 3 06479 Crankcase cover l 19 08366 Oil Seal 3A 07186 Oil Sight Glass wi Gasket H 20 08098 Seal Case 4 08380 O Ring 1 21 06613 O Ring P420 3100 5 12137 Oil Drain Plug 1 21 07266 O Ring P420 5100 SA 07182 Gasket for Oil Drain Plug 1 22 08059 O Ring 5B 08092 Plug with Gasket 1 23 12254 V Sleeve 6 08093 Screw 4 23A 08099 Spacer Ring 6A 08094 Spring Washer 12 23B 12255 Weep Seal 7 08471 Bearing Cover Open 1 24 08376 Pressure Ring 8 08472 Bearing Cover Closed H 25 06373 Weep Return Ring SA 06245 Shim 1 26 06614 Manifold P420 3100 9 01016 O Ring 2 26 06374 Manifold P420 5100 10 08095 Screw with Washer 8 27A 06615 Valve Assembly P420A 3100 11 07459 Radial Shaft Seal 1 27A 06375 Valve Assembly P420A 5100 12 08473 Bearing H 27 06376 Valve Seat 12A 08474 Bearing H 28 08371 Valve Plate 13 08475 Crankshaft 1 29 06377 Valve Spring 14 08091 Fitting Key H 30 08372 Valve Spring Retainer 15 08390 Connecting Rod Assembly 3 31 07212 0001 O Ring Viton P420A 3100 ISA 07311 Screw with Washer 6 31 07212 O Ring P420A 5100 16 06611 Plunger Assy Items 16A 16G 3 32 06616 Plug P420A 3100 16A 08096 Plunger Base 3 32 06379 Plug P420A 5100 16B 08398 Plunger Pipe 3 33 07214 0001 O Ring
4. 18 xw 1 88 xh 3 00 Contact Giant Industries for service school information Phone 419 531 4600 P420A 3100 5100 PUMP DIMENSIONS INCHES MM 6 1 155 58 11 89 300 2 x 3 4 NPT P420A 3100 6 22 158 2 x 3 4 BSPP P420A 5100 oodrutt Key bg Discharge Connection HO or cy SEN SZ 3 5 loa fl j 88 9 dch fe a ie a 29 esye R l k Bp ah Tl Kg KIRCH TUE 2 63 2 96 45 ie lt t 2 PARP ANE 67 GD ea py ipo 0m aS SS L An 5 31 135 2x 3 4 NPT P420A4 3100 3 09 6 22 158 l 2x1 BSPP 4204 5100 8 Inlet 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 Six 6 months from the date of shipment for all rebuilt pumps 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 w
5. IES 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 P O Box 3187 Toledo Ohio 43607 PHONE 419 531 4600 FAX 419 531 6836 www giantoumps com Copyright 2002 Giant Industries Inc 10 02P420A 3100 5100 PM6
6. MPORTANT 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 Use Recommended 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 Poe eD tera iat te a Temperature of Pumped Fluids ccceeceeeseeeees HEERO E le Eeer RENE POLES EE KEE EE SER OF e E E EIERE EE E tee Shart Mouni eebe eege EE Crankcase EE Volumetric Efficiency 1460 2 0 eeeeeeeeeeees Mechanical Efficiency 1460 2 0 eee eeeeeees e Up to 13 0 GPM 49 Im EN Up to 2000 PSI 138 bar EE at 11 GPM EE Up to 140 PSI 9 7 bar ele 24mm MOIE O EIO ee ee Up to 1460 RPM ee 25mm EE Up to 160 F 71 C Eet 2 3 4 BSPP P420A 5100 EE 2 3 4 NP
7. T P420A 3 100 EE 2 3 4 BSPP P420A 5 100 EE 2 3 4 NPT P420A 3 100 ne ATAATA Top of pulley towards fluid end SE 28mm Se Either side keete 36lbs 1loz 0 52 kg E 30fl oz 0 89 liters EE 0 95 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 require ments 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 GPM X PSI _ 1450 P P420A 3100 5100 PULLEY SELECTION amp HORSEPOWER REQUIREMENTS PUMP MOTOR 1000 1500 1700 2000 7 75 450 785 7 0 48 7 2 82 96 7 75 500 900 8 0 5 5 83 94 11 0 7 75 5 75 1010 9 0 6 2 9 3 10 5 12 4 7 75 6 00
8. Triplex Ceramic O e S Plunger Pump Operating Instructions P420A 3100 eae amp P420A 5100 Corrossion Resistant Pumps Contents Installation Instructions page 2 Specifications page 3 Parts List Torque Specs page 4 Recommened Spare Parts List page 4 Exploded View Kits page 5 Repair Instructions pages 6 7 Pump mounting selection Guide page 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 are
9. a 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 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 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 I
10. hich 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 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 WARRANT
11. on 6 Plunger Packing Kits 09140 P420 5100 Item Part Description Qty Valve Assembly Kit P420A 51 00 21 07266 O Ring 3 09478 22 08059 O Ring 3 Item Part Description Qty 23 12254 V Sleeve 3 27A 06375 Valve Assembly Complete 6 33 07214 O Ring 6 23B 12255 Weep Seal 3 24 08376 PressureRing 6 Note Always take time to lubricate all metal and nonmetal parts with a light film of oil before reassembly This step will ensure proper REPAIR INSTRUCTIONS P420A 3100 3100 PUMPS fit at the same time protecting the pump nonmetal parts i e the elastomers from cutting and scoring 1 With a socket wrench 4 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 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 2 5 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 3 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
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