Giant P423, P420, P422, P420-0011, P425 User Manual

...

P400 Series -

22 and 25mm Versions

For Models: P420 P420-0011 P420-0021 P422 P423 P425

Triplex Ceramic

Plunger Pump

Operating Instructions/

Repair and Service Manual

Updated 11/07

Contents:

Installation Instructions: page 2 Pump Specifications (except P425): pages 3-5 Exploded View: page 6 Parts List/Kits: page 7 Pump Specifications (P425): page 8 Repair Instructions/Torque Specs.: pages 9-10 Trouble Shooting Chart: page 11 Recommended Spare Parts List: page 11 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 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 1600 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 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 3-5 and page 8.

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.

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.

2. Pump operation must not exceed rated pressure, volume, or RPM. A pressure relief device must be installed in the discharge of the system.

Use SAE 80-90W or Giant’s p/n 01154 or ISO

VG220 industrial gear lube 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.

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

ModelS P420A, P420A-0011, P420A-0021

U.S. (Metric)

Volume................................................................ Up to 12.9 GPM ................. (48.8 LPM)

Discharge Pressure.............................................. Up to 2175 PSI ................... (150 bar)

Inlet Pressure....................................................... -4.35 to 145 PSI.................. (-.3 to 10 bar)

Stroke .................................................................. 0.945” ................................. (24mm)

RPM .................................................................................................................. Up to 1450 RPM

Plunger Diameter ................................................ 0.98” ................................... (25mm)

Temperature of Pumped Fluids........................... Up to 160

Inlet Ports .......................................................................................................... (2) 1" NPT

Discharge Ports ................................................................................................. (2) 3/4" NPT

Shaft Rotation ..................................................... Top of pulley towards fluid end

Crankshaft Diameter ........................................... 1.1” ..................................... (28mm)

Key Width ........................................................... 0.315” ................................. (8mm)

Shaft Mounting ................................................................................................. Either side

Weight................................................................. 36 lbs. 11oz......................... (16.6 kg)

Crankcase Capacity............................................. 27 fl.oz................................ (0.8 liters)

Volumetric Efficiency @ 1450 ......................................................................... (0.95)

Mechanical Efficiency @ 1450......................................................................... (0.86)

F........................ (71 oC)

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.

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 fill and the oil drain plugs, also. Refer to the repair instructions as necessary for the proper assembly sequence.

P420 HORSEPOWER REQUIREMENTS

RPM GPM 1000 PSI 1500 PSI 1700 PSI 2175 PSI

785 7.0 4.8 7.2 8.2 10.4

900 8.0 5.5 8.3 9.3 12.0 1010 9.0 6.2 9.3 10.5 13.4 1120 9.9 6.8 10.2 11.7 14.9 1240 11.0 7.6 11.4 12.8 16.5 1450 12.9 9.0 13.3 15.1 19.3

HORSEPOWER RATINGS:

The rating shown are the power

requirements for the engine power outputs must be approximately twice the pump power requirements shown above.

We recommend a 1.15 service factor

be specified when selecting an

SPECIAL NOTE:

The theoretical gallons per revolution (gal/rev) is 0.0089. To find specific outputs at various RPM,

electric motor as the power source. To compute specific pump horse power requirements, use the following formula:

use the formula: GPM = 0.0089 x RPM

HP = (GPM X PSI) / 1450

pump. Gas

Specifications

Model P422

U.S. (Metric)

Volume................................................................ Up to 10.7 GPM ................. (37.7 LPM)

Discharge Pressure Continuous .......................... Up to 2600 PSI ................... (180 bar)

Discharge Pressure Intermittent .......................... Up to 3000 PSI ................... (206.8 bar)

Inlet Pressure....................................................... -4.35 to 145 PSI .................. (-.3 to 10 bar)

Stroke .................................................................. 0.94” ................................... (24mm)

RPM .................................................................................................................. Up to 1450 RPM

Plunger Diameter ................................................ 0.87” ................................... (22mm)

Temperature of Pumped Fluids........................... Up to 160

Inlet Ports .......................................................................................................... (2) 1" NPT

Discharge Ports ................................................................................................. (2) 3/4" NPT

Shaft Rotation ..................................................... Top of pulley towards manifold

Crankshaft Diameter ........................................... 1.102” ................................. (28mm)

Key Width ........................................................... 315” .................................... (8mm)

Shaft Mounting ................................................................................................. Either side

Weight................................................................. 36 lbs. 11oz......................... (16.64 kg)

CrankcaseCapacity.............................................. 27 fl.oz................................ (0.8 liters)

Volumetric Efficiency @ 1450 ......................................................................... (0.95)

Mechanical Efficiency @ 1450......................................................................... (0.83)

F........................ (71 oC)

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.

NOTES:

P422 HORSEPOWER REQUIREMENTS

RPM GPM 1000 PSI 1500 PSI 2610 PSI 3000 PSI*

900 6.2 4.3 6.4 11.1 12.8 1050 7.2 5.0 7.5 13.0 14.9 1160 8.0 5.5 8.3 14.3 16.4 1300 9.0 6.2 9.3 16.0 18.4 1450 10.0 6.9 10.4 17.9 20.6

*Intermitent duty only*

SPECIAL NOTE:

The theoretical gallons per revolution

(gal/rev) is 0.0069.

To find specific outputs at various RPM,

use the formula: GPM = 0.0069 x RPM