Giant Coffeemaker p46w User's Manual
Contents
1. 3 02 P46W P46W HK amp P46HT amp P46HT PMO62. GPH X PSI 1460 HP P46W amp P46W HK PULLEY SELECTION amp HORSEPOWER REQUIREMENTS PUMP MOTOR PULLEY PULLEY 7 1 5 7 1 5 7 15 7 15 7 1 5 RPM GPM 1000 PSI 1500 PSI 1700 PSI 2200 PSI Specifications Model P46HT Discharge PCS UNC sessirnir Mlet PressUre ee eer ee meee ee Maximum Crankshaft Rotation Speed Plunger Diameter cccccccccccccccccccecccceceeeeeeeeeeees Ciankcase A ACU sesiesecte oh case teaeney iuri a WT CCA Sos seer pa creeerccdten sed ia HEEP crsacsenicencattanea E A Discharge Ports sscscccccsacanaccunaateacnacienesonceteadsanaeeidion Palley MOUNDE ccesectenssennessaceeentechaeswenseesones Shaft ROATIOD ist decnsnsicsaniaestonitystesusnseecissoadntennds ss POV 1 OE is eee tee E E E Crankshaft cccanctsconaannarsonssaencsanumanataacsdamepsedonepninoad Viscosity 1 Centipoise NPSHR FT HEAD ffeqedaneusueiseecaetecneseannesaes Up to 123 GPH 2 1 PGM A AAA N ETT 900 PSI EE EEEE EEE ETE See NPSHR curve below E E EEEE Up to 220 F EAA AI ET 2 1 2 BSP PTEE AE ES 2 3 8 BSP A EE T N Either Side E AEAT Top of pulley towards head E A N AE EE 16 lbs 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
3. Models D Triplex Ceramic Plunger Pump Operating Instructions Repair and Service Manual 46W P46W HK amp P46HT Updated 3 02 Contents Installation Instructions page 2 Pump Specifications page 3 4 Kits Torque Specs page 5 Pump Mounting Selection Guide page 5 Exploded View page 6 Parts List page 7 Trouble Shooting page 8 Recommended Spare Parts List page 8 Repair Instructions page 9 11 Dimensions back page Warranty Information back page INSTALLATION INSTRUCTIONS P46W P46W HK amp P46HT Installation of the Giant Industries Inc pump is nota 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 assis tance 1 The pump should be installed flat on a base to amaximum ofa 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 itis important to insure a positive head to the pump to prevent cavitation See NPSHR curve for P46HT on page 4 3 The discharge plumbi
4. 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 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 a 7 15 7 1 5 7 15 RPM GPM GPM 200 PSI 2 0 3851091540 01 02 04 06 3 25 6761161960 02 04 07 10 4 25 900 21 123 03 06 09 13 400 PSI 600 PSI 900 PSI P46W P46W HK amp P46HT REPAIR KITS Plunger Packing Kit PA46W 09038 Ceramic Plunger Assembly Kit 09539 Item Part Description Qty Item Part Description Qty 31 07241 V Sleeve 3 24A 07021 Ceramic Plunger 3 40 07234 O Ring 3 24B 08456 Tension Screw 3 24C 07676 Copper Ring 3 Complete Plunger Packing Kit P46W 09081 25 06648 13333 Flinger 3 Item Part Description Qty 31 07241 V Sleeve 3 p n 13333 is needed for olde
5. TRUCTIONS P46W P46W HK P46HT 1 With a22mm socket remove the 2 Remove the discharge spring 3 Useasmall slide hammer to three discharge 43 and three retainer 34 valve spring 35 remove valve seats 37 from inlet 41 manifold plugs Check and valve plate 36 manifold 29 Inspect valve o rings 42 amp 44 for wear and plates 36 and valve seats 37 replace as necessary for wear If excessive pitting is 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 a rubber mallet to remove the inlet valve assembly the two manifold stud nuts 46 dislodge and slide off the 34 40 witha 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 8 The pressure rings item 30 can now be removed by pulling straight out REPAIR INSTRUCTIONS P46W P46W HK amp P46HT 31A P46W HK amp P46HT only 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 Ins
6. ck 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 8 66 6 81 7 ki l e 6mm KEY i 3 14 J 70 INLET 1 2 NPT 4 cid 3 74 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 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 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 wa
7. eeve P46W only 3 24B 08456 Tension Screw 3 50 11512 High Temperature Seal 24C 07676 Copper Ring 3 P46W HK amp P46HT 6 25 06648 Flinger 3 5I 07240 Support Ring Rear V Sleeve 3 26 07206 Radial Shaft Seal 3 52 07109 Plug 1 2 BSP l 26A 11510 Spacer Sleeve 3 52A 07110 Gasket 1 28 07207 Shim Manifold Stud 2 53 13338 Plug 3 8 BSP l 29 07033 Manifold l 53A 08486 Copper Crush Washer 30 07230 Pressure Ring 3 P46W amp P46W HK l 31 07241 V Sleeve P46W only 3 31A 11511 V Sleeve High Temp P46W HK P46HT 3 This will not fit into older P46W pumps with brass retainers 08064 It can only be used with part number 11510 26A You can substitute p n 13333 for 06648 only ifthe brass retainer 08064 is used 7 MALFUNCTION The Pressure and or the Delivery Drops Water in crankcase Noisy Operation Rough Pulsating Operation with Pressure Drop Pump Pressure as Rated Pressure Drop at gun Excessive Leakage High Crankcase Temperature PUMPSYSTEM 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 pump for restrictions Unloader High humidity Worn seals Worn bearings oil with Cavitation Worn packing Inlet restriction Accumulator pressure Unloader Cavitation Restricted discharge plumbing Worn plungers Worn packing seals Excessi
8. ember 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 IMPORTANT OPERATING CONDITIONS Failure to comply with any of these conditions invalidates the warranty l 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 1s 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 VONE eee een eee eee nee ee er eee Discharge Pressure os h ec scececoceetecetcecreretcarscuseteienl MS CTS O a eas asec es cece sees rece ee secccenneeneeeecancees Cramkease Oil Capacity ices cecvaetettenstrcsatievieeeess Temperature of Pumped Fluids c000008 Plunger Diameter cess ete ote ees kdnennataaieneee aes HE POMS e A usenet Discharge POS ecse eceterenaceaseeates Pulley Mount
9. ing oo ccccccccecccccceeeeeeeeeeeeeeeeees Shaft Rotation osoooeeneeneeeessssssseeseeesssssssssssrrrrress Volumetric Efficiency 1420 osseeeeeeesseeseeee Mechanical Efficiency 1420 occ PEE EE Up to 3 9 GPM P EE E 2200 PSI NEEE EAEE ETT 4 35 140 psi E E tenant ateseciaen Up to 1420 RPM E E 14 1mm A E AS Up to 220 F EET 18mm E E 2 1 2 BSP EEE EE 2 3 8 BSP KEE EEE TEETE Either Side T eeree aes Top of pulley towards Head E ain E A ETS 16 lbs TAE AT 0 96 PE E E eect 0 80 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
10. m 8 Steel Pulley 1 gr Exploded View P46W P46W HK P46HT P46W P46W HK amp P46HT PARTS LIST TEM PART DESCRIPTION QTY TEM PART DESCRIPTION QTY l 07222 Crankcase l 32 07231 Support Ring 3 2 07181 Vent Filler Plug with Seal l 33 07232 Pressure Spring 3 2A 07182 Gasket Oil Filler Cap l 34 07325 Retainer Spring 3 08004 Cover Crankcase 1 P46W amp P46HT 6 4 08005 O Ring 1 34 06018 0100 Retainer Spring P46HT 6 5 08008 Oil Dipstick 1 35 06017 0100 Valve Spring 6 6 01009 O Ring l 36 06016 ValvePlate 6 9 07188 Cylinder Screw with Slot 4 37 06014 Valve Seat 6 10 07223 Spring Washer 38 06015 O Ring 6 Excluding P46HT 4 39 07233 Suction Valve Adaptor 3 10 07223 0100 Spring Washer P46HT only 4 40 07234 O Ring Adapter 3 1 08012 Oil Drain Plug with Seal l Al 07235 Plug Manifold Inlet 3 11A 06709 Gasket Oil Drain Plug l 42 12004 O Ring Manifold Plug Inlet 3 12 07224 Bearing Cover 2 43 07034 Plug amp O Ring 14 08015 Radial Shaft Seal 2 P46W amp P46W HK 3 15 08020 Ball Bearing 2 43 07792 Plug amp O Ring P46HT 3 16 07225 Screw and Washer 6 4 07035 O Ring for 43 3 17 07226 Shaft Protector 1 45 07215 Stud Manifold 2 18 07227 Crankshaft l 46 08040 Hex Nut Manifold Stud 2 19 01024 Key l 47 08041 Spring Washer Stud 2 20 08024 Connecting Rod 3 48 07237 Housing Rear V Sleeve l 22 07201 Crosshead Assy 3 49 07238 O Ring Rear 23 01031 Crosshead Pin 3 V Sleeve Housing l 24A 07021 Plunger Pipe 3 50 07239 Rear V Sl
11. mly 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 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 is 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 ba
12. ng 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 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 guidelines 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 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 rem
13. oval may be 12 To replace plunger oil seals manifold firmly against crankcase overcome by heating the 26 proceed to Gear End 1 Replace manifold stud bolts stainless steel plunger base Disassembly section below 45 washers 47 and nut 46 and This will melt any excess loc tite Otherwise continue as de tighten to 35 ft lbs beneath the ceramic plunger scribed below allowing easy removal 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 Replace 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 b
14. r P46W pumps with brass 40 07234 O Ring 3 retainers p n 08064 50 07239 Rear V Sleeve 3 5I 07240 Support Ring Valve Assembly Kit P46W amp P46W HK 09039 Rear V Sleeve 3 Item Part Description Qty 34 07325 Spring Retainer 3 Plunger Packing Kit P46W HK P46HT 09514 gt oo e Item Part Deser onon Qty 36 06016 Valve Plate 3 31A 11511 cia Bove 3 37 06014 Valve Seat 3 40 07234 O Ring Adapter 3 38 06015 O Ring Valve Seat 3 50 11512 High Temp Rear Seal 6 i 07234 O Ring Adapter 3 5 07240 Support Ring 3 42 12004 O Ring Manifold Plug 3 44 07035 O Ring Discharge Plug 3 Valve Assembly Kit P46HT 09497 Item Part Description Qty 34 06018 0100 Valve Cage 3 35 06017 0100 Valve Spring 3 36 06016 Valve Plate 3 37 06014 Valve Seat 3 38 06015 O Ring 3 40 07234 O Ring Adaptor E 42 12004 O Ring Manifold Plug 3 44 07035 O Ring Discharge Plug 3 P46W P46W HK amp P46HT TORQUE SPECIFICATIONS Position Item Description Torque Amount 24B 08456 Tension Screw Plunger 105 in lbs 41 07235 Plug Manifold Inlet 52 ft lbs 43 07034 Plug Manifold Outlet 52 ft lbs 46 08040 Hex Nut Manifold Stud 35 ft lbs Pump Mounting Selection Guide Bushings Rails 01065 18 mm Tapered H Bushing 01034 Steel Box Rails L 9 25 x W 1 18 x H 1 62 Pulley amp Sheaves 01075 Plated Steel Channel Rails 01061 7 75 Cast Iron 1 gr AB Section L 9 00 x W 2 12 x H 2 50 01062 7 75 Cast Iron 2 gr AB Section 01066 18 m
15. rranty 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 WARRANTIES OR REPRESENTATION EXPRESS OR IMPLIED INCLUDING WITHOUT LIMITATION ANY WARRAN WARRANTIES ARE HEREBY DISCLAIMED AND EXCLUDED BY THE MANUFACTURER
16. tall new v sleeves 31 or 50 with grooved sides towards front of pump For P46W HK amp P46HT pumps install high temperature seal 31 A with grooved sides towards front of pump Replace the support rings 32 and pressure springs 33 into manifold 29 Install valve assembly 34 40 into manifold 29 Reinstall manifold plugs 43 and torque plugs to 52 ft lbs 9 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 10 Inspect ceramic plunger 24A 11 Replace copper ring 24C onto 13 Before replacing pump manifold tips for wear If necessary plunger bolt 24B Slide 29 first rotate crankshaft 18 replacement of the ceramic plunger bolt assembly into until two outside plungers 24A plungers may be accomplished ceramic plunger 24A Apply a extend evenly forward Next by removing the plunger bolt light film of loc tite to plunger lubricate v sleeves 50 in the rear assemblies 24B and 24C witha bolt threads and place plunger v sleeve housing 48 and slide 13mm wrench Ceramic assembly onto stainless steel housing over plungers Lubricate plungers should now slide off plunger base 22 and tighten to ceramic plungers with a light film the stainless steel plunger base 105 in lbs of oil Carefully and evenly slide 22 Excessive resistance to manifold over plungers and press plunger rem
17. ve 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 and Replace worn parts Check suction lines on inlet of Check for proper operation Reduce oil change interval Replace seals Replace bearings Refill crankcase 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 Preventative Maintenance Check List amp Recommended Spare Parts List Check Daily Weekly SOhrs Every Every Every 500 hrs 1500 hrs 3000 hrs Oil Level Quality EE ee eee Oil Leaks Cx Water Leaks SE A Belts Pulley OOS y Plumbing a ee ee ee ee ee Recommended copare ar Valve Assembly Kit 1 kit pump See page 5 for kit list Oil Change 1 Gallon p n 1154 Plunger Packing Kits 1 i See page 5 for kit list Oil Seal Kit 1 kit pump See page 5 for kit list a E REPAIR INS
18. y 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 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 a rubber mallet 25 Insert the far side crankshaft oil seal 14 with the Giant Bearing Tool making sure it is fir
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