Page 1
Model
CP460
Triplex Ceramic
Plunger Pump
Operating Instructions/
Repair and Service Manual
Updated 06/17
Contents:
Installation Instructions: page 2
Pump Specications: page 3
Parts List/Torque Specs: page 4
Exploded View/Kits: page 5
Repassembly Instructions: page 6
Dimensions: page 7
Warranty Information back page
Page 2
INSTALLATION INSTRUCTIONS
Operation
Check oil level prior to starting and ensure trouble-free water supply.
Important! The crankcase must be lled with
synthetic motor oil of class SAE 0W 40 when
pumping CO
Initial oil change after 50 operating hours and
then every 500 hours, after 1 year if used less.
Caution when operating in damp places or
with high temperature uctuations. Oil must be
changed immediately should condensate (frothy
oil) occur in the gear box.
NPSH values must be observed.
Maximum input pressure is 1200 PSI (83 bar).
The maximum suction head is 14.5 PSI (1 bar).
Make sure that suction pulsation is sufciently
dampened - water column resonance must be
avoided.
Important! If the pump is not used for a long pe-
riod of time, it is possible the seals (23/238) could
become hard or brittle thus causing the pump
to leak when put into operation.
If this is the case, we recommend these seals be
replaced every 4 years.
under 0° C.
2
Safety Rules
A safety valve is to be installed in accordance
with the guidelines for liquid spraying units so
that the admissible operating pressure cannot be exceeded by more than 10%. Pump
operation without a safety valve as well as any
excess in temperature or speed limits automatically voids the warranty.
When the pump is in operation, the drive shaft
end and the coupling must be enclosed by a
protective cover or a coupling bell.
Pressure in the discharge line and pump must
be at zero before any maintenance to the
pump takes place. Shut off suction line. Disconnect fuses to ensure that the driving motor
does not get switched on accidently. Make sure
that all parts on the pressure side of the unit
are vented before starting the pump. In order
to prevent air, or an air-water mixture being
absorbed and to prevent cavitation occurring,
the pump NPSHR (=suction head) and water
temperature must be respected.
Cavitation and/or compression of gases
lead to uncontrollable pressure-kicks which
can ruin pump and unit parts and also be
dangerous to the operator or anyone standing nearby.
Giant Plunger Pumps are suitable for pumping
clean water and other non-aggressive or non-
abrasive media with a specic weight similar to
water.
Before pumping other liquids • especially
Inammable, explosive and toxic media -
the pump manufacturer must be consulted
with regard to the resistance of the pump
material. It is the responsibility of the equipment manufacture and/or operator to ensure that all pertinent safety regulations are
adhered to.
2
Page 3
CP460 Pump Specications
U.S. Metric
Volume .................................................... 1.6 GPM ............................................................6.2 L/min
Discharge Pressure ................................ 6000 PSI .............................................................. 580 Bar
Inlet Pressure .......................................... 14-1200 PSI ........................................................ 1-83 Bar
Stroke .....................................................0.98” .......................................................................24 mm
Speed ....................................................................................................................... Up to 750 RPM
Plunger Diameter .................................... 0.55” ...................................................................... 14 mm
Temperature of Pumped Fluids ...............-40
Inlet Ports .................................................................................................................... (2) x 1/2” BSP
Discharge Ports .......................................................................................................... (2) x 3/8” BSP
Shaft Rotation ................................................................................... Top of pulley towards uid end
Crankshaft Diameter ............................... 1.10” ....................................................................... 28 mm
Key Width ...............................................0.31” .........................................................................8 mm
Shaft Mounting .................................................................................................................Either side
Weight ..................................................... 46 lbs. .....................................................................21 KG
Crankcase Capacity ................................ 27 .oz. ................................................................ 0.8 Liter
Consult the factory for special requirements that must be met if the
pump is to operate beyond one or more of the limits specied above.
o
F to 160 oF ..........................................-40 oC to 70 oF
1
1
NOTES:
In order to drive the pump from the side opposite the present shaft extension, 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 ll and the oil drain plugs,
also. Refer to the repair instructions as necessary for the proper assembly sequence.
HORSEPOWER RATINGS:
The rating 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 a 1.15 service factor be speci-
ed when selecting an electric motor as the
power source. To compute specic pump horse
power requirements, use the following formula:
HP = (GPM X PSI) / 1450
CP460 Horsepower Requirements
RPM GPM 3000
PSI
4000
PSI
5000
PSI
6000
PSI
350 0.75 1.6 2.1 2.6 3.1
450 0.96 2.0 2.7 3.3 4.0
550 1.2 2.5 3.3 4.1 5.0
650 1.4 2.9 3.9 4.8 5.8
750 1.6 3.3 4.4 5.5 6.6
3
Page 4
Exploded View - CP460
Note: Do not use mineral oil on seals and o-rings.
Use silicone grease only.
Plunger Packing Kits
Part # CP09499-0023
Item Part # Description Qty.
21 07266-0003 O-Ring 3
23 04762 Grooved Seal Packing 3
23A 04763 Support Ring 3
23B 04581 Grooved Seal, Teon 3
24 04582 Pressure Ring 3
25A 04764 Support Ring 6
25B 06818 O-Ring 6
CP460 REPAIR KITS
Valve Assembly Kits
Part # CP09498-0003
Item Part # Description Qty.
27A 05543 Valve Assembly 3
33 05545-0003 O-Ring 3
Oil Seal Kit
Part # CP09641
Item Part # Description Qty.
19 05444 Oil Seal 3
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Page 5
CP460 PARTS LIST
ITEM PART DESCRIPTION QTY.
1 08377 Crankcase 1
2 08378 Oil Fill Plug with Gasket 1
3 06479 Crankcase Cover 1
3A 07186 Oil Sight Glass w/Gasket 1
4 08380 O-Ring 1
5 07109 Oil Drain Plug 1
5A 06015 O-Ring 1
5B 08092 Plug with Gasket 1
6 01010 Screw 4
6A 01011-0400 Spring Washer 4
7 04739 Bearing Cover 1
8 05291 Bearing Cover Closed 1
8A 05292 Shim 1-3
8B 05293 Shim 1
9 01016 O-Ring 2
10 07114 Screw with Washer 8
11 07459 Radial Shaft Seal 1
12 05350 Bearing 2
13 04741 Crankshaft 1
13A 04742 Spacer Ring 1
14 08091 Fitting Key 1
15 08390 Connecting Rod Assy. 3
16 06480 Plunger Assembly 3
17 06790 Crosshead Pin 3
19 05444 Radial Shaft Seal 3
ITEM PART DESCRIPTION QTY.
20 05938 Seal Adapter 3
20A 04761 Seal Case 1
20B 04767 Set Screw 4
21 07266-0003 O-Ring 3
23 04762 Grooved Seal Packing 3
23B 04581 Gooved Seal, Teon 3
24 04582 Guide Ring 3
25 06485 Seal Case 3
25A 04764 Support Ring 6
25B 06818 O-Ring 6
26 06488 Valve Casing 1
27A 05543 Valve Assy. 6
(Includes items 27-31)
27 05541 Valve Seat 6
28 05542 Valve Plate 6
29 07906 Valve Spring 6
30 07907 Spring Tension Cap 6
31 07770-0003 O-Ring 6
32 08406-0100 Plug 3
33 05545-0003 O-Ring 3
34 06494 Cap Screw 8
36 04369 Plug, 3/8” BSP 1
37 08486 Copper Washer 1
38 07109-0400 Plug, 1/2” BSP 1
39 06272 Copper Washer 1
CP460 TORQUE SPECIFICATIONS
Item Part # Description Torque Amount
5 07109 Oil Drain Plug 30 ft.-lbs. (40 Nm)
15A 07311 Screw with Washer 98 in.-lbs. (11 Nm)
32 08406-0100 Plug 111 ft.-lbs. (150 Nm)
34 06494 Cap Screw 30 ft.-lbs. (40 Nm)
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Page 6
Repair Instructions - CP460 Pumps
Note: All o-rings and seals must not come into contact with mineral oil. Use silicone grease only.
Inlet Valves
Remove inner hexagon screws (34) and pull off valve casing (26) to the front. Take out seal case (25) from valve casing
(26). Remove the exposed inlet valve with a pair of at nose pliers and the valve seat (27) with a valve puller. Disassemble parts and examine valve plate (28), valve seat (27), O-ring (31) and support ring (31A). Replace worn parts.
Tighten inner hexagon screws (34) again to 30 ft-lbs. (40 Nm).
Discharge Valves: With a socket 32mm wrench, screw out valve plugs (32) . Remove the exposed discharge valves
with a pair of at nose pliers and the valve seat (27) with a valve seat puller. Disassemble parts and examine valve
plate (28), valve seat (27), and O-rings (31, 33). Replace worn parts. Take care to reassemble in correct sequence.
Tighten plugs (32) to 111 ft-lbs. (150 Nm).
Seals
Remove oil drain plug (5) and drain oil. Remove inner hexagon screws (34) and pull off valve casing (26) frontwise over
the plungers (16).
Important! if the seal casing (20A) does not separate from the valve casing (26), press both casings apart by placing
two at screwdrivers in the side notches on the sal casing (20A). Be careful not to damage casing surfaces.
Remove seal cases (25) situated either in valve casing (26) or seal casing (20A). Separate seal casing (20A) from seal
retainers (20). Remove grooved ring (23) and guide ring (24) from the seal casing (20A). Examine O-rings (25B) and
support rings (25A) attached to seal casing (26). Check seal ring (23A) situated between valve casing and seal casing,
and replace if necessary. Then remove seal retainers (20) from crankcase (1). Pull grooved ring (23) out of seal retainer
(20). Check O-ring (21). Grease new seals and O-rings with silicone grease before reinstallation.
Important! Seal casing (20A) has a notched pin to ensure correct tting. Reassemble parts in the proper sequence.
Important! The grooved seal (23) on the high-pressure side is to be tted carefully into the seal casing (20A) using a
22mm plastic rod. Under no circumstances must the surface in the seal casing or the seal lip of the grooved seal be
damaged.
Check surfaces of plunger (16). Damaged surfaces cause hard wear on seals. Deposits of all kinds must be removed
from the plungers.
Important! The plunger surfaces are not to be damaged. If there are lime deposits in the pump, care must be taken
that the drip-return bore in parts (25) and (26) ensure trouble-free drip-return.
If the plunger (16) is worn, the complete plunger must be changed. The ceramic pipe alone cannot be changed due to
reasons of precision. When reassembling tighten inner hexagon screw (34) to 30 ft-lbs. (40 Nm).
If the plunger (16) is worn, the complete plunger must be changed (see below). The ceramic pipe alone cannot be
changed due to reasons of precision. When reassembling tighten inner hexagon screw (34) to 30 ft-lbs (40 Nm).
Gear and Plunger
If oil leaks where the plunger (16) protrudes out of the gear, gear seals (19) and plungers have to be examined and
replaced as necessary.
Gear Seal
Remove plug (5) and drain oil. Remove valve casing as described above. Take seal adapter (20) off plunger (16) and
replace gear seal (19).
Plungers
Drain oil and remove crankcase cover (3). Take off screws on con rods (15). Be careful not to mix up the con rod
halves. Push con rod shaft as far as possible into the crosshead guide. Loosen screws (10) and remove bearing covers
(7&8) with the help of a screw-driver.
Take crankshaft out carefully so as not to bend the con rods. Remove and dismantle con rods and plungers (18). Replace worn parts. Connecting rods must be installed in the sme position and orientation.
To reinstall, insert con rods and plungers, put crankshaft in carefully and then push the bearing covers (7&8) onto the
ends of the crankshaft. Screw on bearing covers with screws (10). Mount con rod halves and tighten screws (15) to 8
in-lbs. (11Nm). Mount crankcase cover (3) together with O-ring (4).
To rotate crankshaft to the opposite side.
The shaft end is on the left side of the pump looking at it from behind. If it should be on the other side, the valve casing
(26) and seal casing (20A) have to be removed, turned by 180
that the leakage holes are underneath. Oil dipstick (2) and oil drain plug (58) have to be interchanged and crankcase
cover turned by 180
o
.
o
and then put on again. Turn seal adapters (20) 180o, so
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Page 7
Model CP460 Dimensions in(mm)
7
Page 8
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:
One (1) year from the date of shipment for all other Giant industrial and consumer
pumps.
This warranty is limited to repair or replacement of pumps and accessories of which the manufac-
turer’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.
2. Normal wear and tear to standard wear parts.
3. Use of repair parts other than those manufactured or authorized by Giant.
4. Improper use of the product as a component part.
5. Changes or modications made by the customer or third party.
6. The operation of pumps and or accessories exceeding the specications 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 work-
manship 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 war-
ranty 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 WAR-
RANTIES OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE AND ALL SUCH
WARRANTIES ARE HEREBY DISCLAIMED AND EXCLUDED BY THE MANUFACTURER.
SOLD EXCLUSIVELY THROUGH AQUA BLAST
1025 W. Commerce Drive, Decatur, IN 46733
PHONE (260) 728-4433, FAX (260) 728-4517, www.aquablast.com
Copyright 2017 Giant Industries, Inc.
06/17 CP460.indd
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