Giant Saw Triplex Ceramic Plunger Pump User's Manual
Contents
1. PUMP MOTOR RPM GPM 1000 PSI 1500 PSI 1700 PSI 2200 PSI PULLEY PULLEY 7 15 7 15 7 1 9 119 7 15 3 8 EEr sa hio si 21 32 se 47 Specifications Model P46HT VOUTE ace a E AE E N Up to 123 GPH 2 1 PGM Doc bi e P SE or are de Seas ceases eeeiaerniueeereeeiacens 900 PSI PEE PC S500 a e E AEE EE PEE E E T EE See NPSHR curve below Maximum Crankshaft Rotation Speed sccassssiseinvesvrscexecaeescsadestsntesseveereiencsens 900 RPM Puneet D me e E E 18mm Crk OAS mae a E E E EE 8 fl oz EEEE C2 EO E AEE O EET Up to 220 F E PO eaa aA E es 2 1 2 BSP Precht e Po a E 2 3 8 BSP Paley Nan E a E earens oh aneeeeoaacotes Either Side RO O EE E E EEE Top of pulley towards head Mo a E E E 16 Ibs Faia A a E E EE 18 mm w s v z KI c L oO Pa S bAT Zee Pa w Pt ert rag aT i ieee tt s ITTIA tT tt tt O a a a eee AT a TSS a TT Lu iti Tt yt ty yt u gz TSS I a SJJ a Z AASTAST 200 400 600 800 1000 1200 1400 1600 1700 RPM NPSHR Chart 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 Select2. 0100 08012 06709 07224 08015 08020 07225 07226 07227 01024 08024 07201 01031 07021 08456 07676 06648 07206 11510 07207 07033 07230 07241 11511 P46W P46W HK amp P46HT PARTS LIST DESCRIPTION Crankcase Vent Filler Plug with Seal Gasket Oil Filler Cap Cover Crankcase O Ring Oil Dipstick O Ring Cylinder Screw with Slot Spring Washer Excluding P46HT Spring Washer P46HT only Oil Drain Plug with Seal Gasket Oil Drain Plug Bearing Cover Radial Shaft Seal Ball Bearing Screw and Washer Shaft Protector Crankshaft Key Connecting Rod Crosshead Assy Crosshead Pin Plunger Pipe Tension Screw Copper Ring Flinger Radial Shaft Seal Spacer Sleeve Shim Manifold Stud Manifold Pressure Ring V Sleeve P46W only V Sleeve High Temp P46W HK P46HT QTY A e e FS FSF e e e ITEM PART 32 07231 33 07232 34 07325 34 06018 0100 35 06017 0100 36 06016 37 06014 38 06015 39 07233 40 07234 41 07235 42 12004 43 07034 43 07792 44 07035 45 07215 46 08040 47 08041 48 07237 49 07238 50 07239 50 11512 31 07240 32 07109 52A 07110 53 13338 53A 08486 DESCRIPTION Support Ring Pressure Spring Retainer Spring P46W amp P46HT Retainer Spring P46HT Valve Spring Valve Plate Valve Seat O Ring Suction Valve Adaptor O Ring Adapter Plug Manifold Inlet w wnwonwnrninw Vann on O Ring Manifold Plug Inlet 3 Plug amp O Ring P46W amp P46
3. 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 requirements for the pump Gas engine power outputs must be approxi mately 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 PSI 1440 HP P46HT PULLEY SELECTION amp HORSEPOWER REQUIREMENTS PUMP MOTOR PULLEY PULLEY 7 75 2 0 385 09 540 01 02 04 06 02 04 7 75 _ 3 25 676 1 6 96 0 RPM GPM GPM 200 PSI 400 PSI 600 PSI 900 PSI 07 10 0 7 75 4 25 900 2 1 123 03 06 o9 13 P46W P46W HK amp P46HT REPAIR KITS Plunger Packing Kit P46W 09038 Item Part Description Qty 31 07241 V Sleeve 3 40 07234 O Ring 3 Complete Plunger Packing Kit P46W 09081 Item Part Description Qty 31 07241 V Sleeve 3 40 07234 O Ring 3 50 07239 Rear V Sleeve 3 51 07240 Support Ring Rear V Sleeve 3 Plunger Packing Kit P46W HK P46HT 09514 Ceramic Plunger Assembly Kit 09082 Item 24A 24B 24C 25 Part Description Qty 07021 Ceramic Plunger 3 08456 Tension Screw 3 07676 Copper Ring 3 06648 13333 Flinger 3 p n 13333 i
4. 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 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 Giant synthetic or SAE 90 Gear 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 Specifications Model P46W P46W HK VOTIC eonen ee reenter ert en tr ener rene E er er Discharge PRESSURE srsexnccnareesdnatevarascceancncensteoneevnes Inlet TS Re as hchesc eee ced ices inna a a Maximum Crankshaft Rotation Speed ce ne nS er ee en eee Crankcase Oil Capac i y sssscsccercscciasexestentcesedessvees Temperature of Pumped Fluids eee PR i TCU sessa Gaol elas N EE E ee eran rrr tre WSC TAG e WP OS ee Pulley OU as aos ecpcecre censors ceutnecesteraeianeesaens Shaft RO A100 x sisssiagsasc
5. the stainless steel plunger base This will melt any excess loc tite beneath the ceramic plunger allowing easy removal 11 Replace copper ring 24C onto plunger bolt 24B Slide plunger bolt assembly into ceramic plunger 24A Apply a light film of loc tite to plunger bolt threads and place plunger assembly onto stainless steel plunger base 22 and tighten to 105 in lbs 12 To replace plunger oil seals 26 proceed to Gear End Disassembly section below Otherwise continue as de scribed below 1 The rear V sleeve housing 48 may be removed by prying evenly outward with a flat screwdriver After slipping housing over plunger inspect seals 50 and O ring 49 and replace as necessary Go Before replacing pump manifold 29 first rotate crankshaft 18 until two outside plungers 24A extend evenly forward Next lubricate v sleeves 50 in the rear v sleeve housing 48 and slide housing over plungers Lubricate ceramic plungers with a light film of oil Carefully and evenly slide manifold over plungers and press manifold firmly against crankcase 1 Replace manifold stud bolts 45 washers 47 and nut 46 and tighten to 35 ft Ibs NOTE Contact Giant Industries for Service School Information Phone 419 531 4600 10 REPAIR INSTRUCTIONS P46W P46W HK amp P46HT Gear End Disassembly 14 Remove the crankcase cover bolts 9 Inspect the crancase cover O ring 4 for wear Repl
6. the crankcase 28 Replace near side bearing on crankshaft 18 and mallet to tap into place 29 Take the crankshaft 18 end with the bearing and insert the other end through the bearing housing carefully threading the lobes of the crankshaft through the well lubricated connecting rods 20 Turning the crankshaft while tapping it through the connecting rods will help prevent binding and possiable damage to the connecting rods Continue tapping the crankshaft through the connecting rods 20 until it 1s firmly seated into far side bearing 30 Insert the near side crankshaft oil seal 14 making sure it is firmly seated and well oiled Replace the bearing cover 12 and tighten securely 31 See instructions 13 above for re installing fluid end onto gear end 32 Clean the back edge of crankcase and replace the crankcase cover Be careful not to pinch the crankcase cover o ring 33 Fill the P46W crankcase with 8 oz of Giant oil and check the oil level with the dipstick Proper level is center of two lines Reinstall the pump into your system 11 P46W P46W HK amp P46HT DIMENSIONS 6 81 8 66 5 31 j es ee a ae l g i l n 6mm KEY 4x MB 3 14 l ee INLET 1 2 NPT 3 74 4 92 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
7. 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 gun 4 Use of a dampener is necessary to minimize pulsation 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 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 designated by the arrows on the pump crankcase Reverse rotation may be safely achieved by following a few guide lines available upon request from Giant Industries Inc Required horsepower for system operation can be obtained from the charts on pages 3 4 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 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
8. 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 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 com Copyright 1998 Giant Industries Inc 5 01 P46W P46W HK amp P46HT amp P46HT PM6
9. 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 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 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
10. Triplex Ceramic Plunger Pump Wy l Operating Instructions O e S Repair and Service Manual 46W P46W HK amp P46HT p Contents Installation Instructions page 2 Pump Specifications page 3 4 Kits Torque Specs page 5 Exploded View page 6 Parts List page 7 Trouble Shooting page 8 Repair Instructions page 9 11 Dimensions back page Updated 5 01 Warranty Information back page INSTALLATION INSTRUCTIONS P46W P46W HK amp P46HT 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 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 inclina tion 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 P46W 190 F P46W HK or 220 F P46HT it is important to insure a positive head to the pump to prevent cavitation See NPSHR curve for P46HT on page 4 3 The discharge plumbing from the pump should be properly sized to the flow rate to prevent line pressure loss to the
11. W HK Plug amp O Ring P46HT O Ring for 43 Stud Manifold Hex Nut Manifold Stud Spring Washer Stud Housing Rear V Sleeve O Ring Rear V Sleeve Housing Rear V Sleeve P46W only High Temperature Seal P46W HK amp P46HT N N N WD WD O Go 6 Support Ring Rear V Sleeve 3 Plug 1 2 BSP Gasket Plug 3 8 BSP Copper Crush Washer P46W amp P46W HK You can substitute p n 13333 for 06648 only if the brass retainer 08064 is used f 1 1 1 MALFUNCTION The Pressure and or the Delivery Drops Water in crankcase Noisy Operation Rough Pulsating Operation with Pressure Drop Pump Pressure as Drop at gun Rated Pressure Excessive Leakage High Crankcase Temperature 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 8 PUMP SYSTEM MALFUNCTION REMEDY Replace packing seals Replace spring Tighten or Replace belt Replace nozzle Clean valve assembly Clean strainer Repair Replace hos
12. ace if necessary 15 Inspect the dip stick 5 vent hole for signs of clogging Clean if necessary 16 To remove the crankshaft 18 first remove the bearing cover plates 12 Remove the key 19 17 Hold the pump rear assembly with a wooden fixture or other suitable device in order to secure it while removing the crankshaft 18 Using a plastic mallet tap the crankshaft 18 from one side while turning it from the other side The turning insures that during this sequence the crankshaft does not become wedged agaisnt the connecting rods 20 The far side bearing 15 will remain in the crancase 1 When free the crankshaft 18 can be removed by hand 18 The crankshaft bearing 15 remains on the crankshaft 18 as it is removed The near side crankshaft seal 14 will be removed by this procedure 19 If necessary use a bearing puller to remove crankshaft bearing 15 20 Remove the connecting rod 20 and plunger rod crosshead assembly 22 from the rear of the pump by pulling straight out of the crosshead guides 21 To remove the crankcase oil seal 26 tap oil seal out from the rear of the crankcase using a dowel and rubber mallet The area onto which the oil seal rests should be clean and dry Put a small drop of loc tite on the oil seals and place into crankcase with clips facing the rear of the pump 22 To remove the crosshead pin 23 from the crosshead 22 the assembly should be positioned on a wooden fixture to avoid damage to
13. crosshead Drive out pin 23 on opposite side of mark on the crosshead On those pumps without mark on crosshead drive out pin by tapping on tappered side of pin 23 To remove the bearing remaining in the crankcase insert small end of Giant Bearing tool and tap with a rubber mallet untill bearing and seal are completely removed The bearing can only be removed from the inside by inserting the Giant Bearing Tool through the opposite side of the crankcase 1 and should be inspected for possible damage Gear End Reassembly 24 To reassemble place the far bearing in the crankcase bearing housing and with the Giant Bearing tool as a driver tap into the crankcase 1 using arubber mallet 25 Insert the far side crankshaft oil seal 14 with the Giant Bearing Tool making sure it is firmly seated and well oiled Always make sure that the crankshaft seal 14 lip does not show signs of wear Replace the bearing cover 12 and tighten securely 26 Replace the connecting rod 20 and plunger rod crosshead assembly 22 by press fitting the crosshead pin 23 Make sure to insert the beveled edge of the crosshead pin into crosshead If the crosshead has a mark install pin frommarked side The crosshead pin 23 should not extend beyond either side of the crosshead in order to prevent damage to the crosshead bore of the crankcase 27 Place each crosshead plunger assembly 22 into the pump making sure that all of the parts are well oiled before insertion into
14. e 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 leaks correctly sized inlet 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 REPAIR INSTRUCTIONS P46W P46W HK P46HT 1 With a 22mm socket remove 2 Remove the discharge spring 3 Use a small slide hammer to the three discharge 43 and retainer 34 valve spring 35 remove valve seats 37 from three inlet 41 manifold plugs and valve plate 36 manifold 29 Inspect valve Check o rings 42 amp 44 for plates 36 and valve seats 37 wear and replace as necessary for wear If excessive pitting 1s seen replace the worn parts Check valve seat o ring 38 for wear and replace as necessary 4 Drain the oil from the pump 5 Tap the back of the manifold 6 From the front inlet valve ports Turn the pump over to remove 29 with arubber mallet to remove the inlet valve assembly th
15. e two manifold stud nuts 46 dislodge and slide off the 34 40 with a 17mm wrench pump 7 Inspect and clean the valve assembly parts If pitted or worn replace inlet valve seats 37 valve plates 36 spring 35 and spring retainers 34 Reinsert items 34 38 into valve adapter 39 NOTE Contact Giant Industries for Service School Information Phone 419 531 4600 9 REPAIR INSTRUCTIONS P46W P46W HK amp P46HT 31 50 31A P46W HK amp P46HT only The pressure rings item 30 can now be removed by pulling straight out Inspect and clean manifold 29 and pressure ring Replace if necessary From the front of the pump reinstall pressure rings into manifold 29 with grooved side towards front of manifold Install new v sleeves 31 or 50 with grooved sides towards front of pump For P46W HK amp P46HT pumps install high temperature seal 31A with grooved sides towards front of pump Replace the support rings 32 and pressure springs 33 into mani fold 29 Install valve assembly 34 40 into manifold 29 Reinstall manifold plugs 43 and torque plugs to 52 ft Ibs 10 Inspect ceramic plunger 24A tips for wear If necessary replacement of the ceramic plungers may be accomplished by removing the plunger bolt assemblies 24B and 24C with a 13mm wrench Ceramic plungers should now slide off the stainless steel plunger base 22 Excessive resistance to plunger removal may be overcome by heating
16. ieesnaoaiecicachesnessqveneiaasersepenas Volumetric Efficiency 1420 oes Mechanical Efficiency 1420 0 eeeeeeees EEN PEE E T eee Up to 3 9 GPM E eee 2200 PSI a 4 35 140 psi E E Up to 1420 RPM EEEE A ERE ee 14 1mm E E Up to 220 F ee en AAA 18mm EE E EE 2 1 2 BSP EEEE EEEN EA 2 3 8 BSP N PEE PEE E eer er Either Side PEE OE ETET Top of pulley towards Head m E AE E T 16 Ibs ee 0 96 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 GPH X PSD 1460 HP P46W amp P46W HK PULLEY SELECTION amp HORSEPOWER REQUIREMENTS
17. s needed for older P46W pumps with brass retainers p n 08064 Valve Assembly Kit P 46W amp P46W HK 09039 Item 34 35 36 37 38 40 42 44 Part Description Qty 07325 Spring Retainer 3 06017 0100 Valve Spring 3 06016 Valve Plate 3 06014 Valve Seat 3 06015 O Ring Valve Seat 3 07234 O Ring Adapter 3 12004 O Ring Manifold Plug 3 07035 O Ring Discharge Plug 3 Valve Assembly Kit P46HT 09497 Item 34 35 36 37 38 40 42 44 Part 06018 0100 Valve Cage 06017 0100 Valve Spring 06016 06014 06015 07234 12004 07035 Description Valve Plate Valve Seat O Ring O Ring Adaptor O Ring Manifold Plug 3 O Ring Discharge Plug 3 BW W WwW W WwW P46W P46W HK amp P46HT TORQUE SPECIFICATIONS Item Part Description Qty 31A 11511 Sleeve 3 40 07234 O Ring Adapter 3 50 11512 High Temp Rear Seal 6 ot 07240 Support Ring 3 Position ltem Description 24B 08456 Tension Screw Plunger 41 07235 Plug Manifold Inlet 43 07034 Plug Manifold Outlet 46 08040 Hex Nut Manifold Stud Torque Amount 105 in lbs 52 ft lbs 52 ft lbs 35 ft lbs Exploded View P46W P46W HK P46HT 10 11 11A 12 14 15 16 17 18 19 20 22 23 24A 24B 24C 239 26 26A 28 29 30 31 31A This will not fit into older P46W pumps with brass retainers 08064 It can only be used with part number 11510 26A PART 07222 07181 07182 08004 08005 08008 01009 07188 07223 07223
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