Giant P430A, P440A, P400 Series, P450A, P455 Operating Instructions/ Repair And Service Manual
...
P400 Series -
18mm Versions
For Models:
P430
P440
P450
P455
Triplex Ceramic
Plunger Pump
Operating Instructions/
Repair and Service Manual
Updated 12/06
Contents:
Installation Instructions: page 2
Pump Specifications: pages 3-5
Exploded View: page 6
Parts List/Kits: page 7
Repair InstructionsTorque Specs.: pages 8-9
Trouble Shooting Chart: page 10
Recommended Spare Parts List: page 10
Dimensions: page 11
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 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 area to protect the
pump from pressure spikes in the event of a blockage or
the use of a shut-off gun.
0
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.
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.
Use SAE 80-90W or Giant’s p/n 01154
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.
2
Specifications
Model P430A
U.S...................................... (Metric)
Volume............................................................... Up to 6.7 GPM .................. (25.4 LPM)
Discharge Pressure Continuous ....................... Up to 3200 PSI .................. (220.6 bar)
Inlet Pressure ...................................................... -4.35 to 145 PSI ................ (-.3 to 10 bar)
Stroke.................................................................. 0.945” ................................ (24mm)
RPM .................................................................................................................. Up to 1450 RPM
Plunger Diameter ............................................... 0.708” ................................ (18mm)
Temperature of Pumped Fluids ........................ Up to 160
Inlet Ports ......................................................................................................... (2) 3/4" 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............................................ 30 fl.oz............................... (0.89 liters)
Volumetric Efficiency @ 1450 ...................................................................... (0.95)
Mechanical Efficiency @ 1450 ...................................................................... (0.83)
o
F ...................... (71 oC)
1
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.
P430 HORSEPOWER
REQUIREMENTS
1000
2000
3000
RPM GPM
920 4.8 3.3 6.6 9.9 10.6
1050 5.4 3.7 7.4 11.2 11.9
1185 6.1 4.2 8.4 12.6 13.5
1315
1450
PSI
PSI
6.8 4.7 9.4 14.1 15.0
7.5 5.2 10.3 15.5 16.6
6.7
PSI
3200
PSI
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
electric motor as the power source.
SPECIAL NOTE:
The theoretical gallons per revolution
(gal/rev) is 0.0046.
To compute specific pump horse
power requirements, use the
following formula:
To find specific outputs at various RPM, use
the formula: GPM = 0.0046 x RPM
pump. Gas
HP = (GPM X PSI) / 1450
3
Specifications
Model P440A
U.S...................................... (Metric)
Volume............................................................... Up to 5.5 GPM .................. (20.8 LPM)
Discharge Pressure Continuous ....................... Up to 4000 PSI .................. (275.3 bar)
Inlet Pressure ...................................................... -4.35 to 145 PSI ................ (-.3 to 10 bar)
Stroke.................................................................. 0.787” ................................ (20mm)
RPM .................................................................................................................. Up to 1450 RPM
Plunger Diameter ............................................... 0.708” ................................ (18mm)
Temperature of Pumped Fluids ........................ Up to 160
Inlet Ports ......................................................................................................... (2) 3/4" 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............................................ 30 fl.oz............................... (0.89 liters)
Volumetric Efficiency @ 1450 ...................................................................... (0.95)
Mechanical Efficiency @ 1450 ...................................................................... (0.82)
o
F ...................... (71 oC)
1
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.
P440 HORSEPOWER
REQUIREMENTS
1000
2000
3000
RPM GPM
920 3.5 2.4 4.9 7.3 9.7
1050 4.0 2.8 5.5 8.3 11.1
1185
1315
1450
PSI
PSI
4.5 3.1 6.3 9.4 12.5
5.0 3.5 6.9 10.4 13.9
5.5 3.8 7.7 11.5 15.3
PSI
4000
PSI
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
electric motor as the power source.
SPECIAL NOTE:
The theoretical gallons per revolution
(gal/rev) is 0.00383.
To compute specific pump horse
power requirements, use the
following formula:
To find specific outputs at various RPM,use
the formula: GPM = 0.00383 x RPM
HP = (GPM X PSI) / 1450
pump. Gas
4
Specifications
Model P450A/P455
U.S...................................... (Metric)
Volume............................................................... Up to 5.5 GPM .................. (20.8 LPM)
Discharge Pressure Continuous ....................... Up to 5000 PSI .................. (344.7 bar)
Inlet Pressure ...................................................... 90 PSI................................. (6.2 bar)
Stroke.................................................................. 0.787” ................................ (20mm)
RPM .................................................................................................................. Up to 1450 RPM
Plunger Diameter ............................................... 0.708” ................................ (18mm)
Temperature of Pumped Fluids ........................ Up to 160
Inlet Ports ......................................................................................................... (2) 1/2" BSP
Discharge Ports ................................................................................................ (2) 1/2" BSP
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............................................ 30 fl.oz............................... (0.89 liters)
Volumetric Efficiency @ 1450 ...................................................................... (0.92)
Mechanical Efficiency @ 1450 ...................................................................... (0.86)
o
F ...................... (71 oC)
1
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.
P450/P455 HORSEPOWER
REQUIREMENTS
2000
3000
4000
RPM GPM
800 3.0 4.2 6.3 8.4 10.5
933 3.5 4.9 7.3 9.8 12.2
1066 4.0 5.6 8.4 11.1 13.9
1200
1450
PSI
PSI
4.5 6.3 9.4 12.5 15.7
5.5 7.6 11.4 15.2 18.9
PSI
5000
PSI
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
electric motor as the power source.
SPECIAL NOTE:
The theoretical gallons per revolution
(gal/rev) is 0.00379.
To compute specific pump horse
power requirements, use the
following formula:
To find specific outputs at various RPM,
use the formula: GPM = 0.00379 x RPM
pump. Gas
HP = (GPM X PSI) / 1450
5
EXPLODED VIEW - P430/P440, P450, AND P455 PUMPS
6
P430, P440, P450 and P455 SPARE PARTS LIST
C = P430 D=P440 E=P450 F=P455
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 07606 Oil Drain Plug 1
5A 07182 Gasket for Oil Drain Plug 1
5B 08092 Plug with Gasket 1
6 01010 Screw 4
6A 01011 Spring Washer 4
7 08471 Bearing Cover Open 1
8 08472 Bearing Cover Closed 1
8A 06245 Shim 1
8B 06330 Shim (May not be present) 1
9 01016 O-Ring 2
10 07114 Screw with Washer 8
11 07459 Radial Shaft Seal 1
12 08473 Bearing 1
12A 08474 Bearing 1
13 08475 Crankshaft (C) 1
13 08482 Crankshaft (D,E,F) 1
14 08091 Fitting Key 1
15 08390 Connecting Rod Assembly 3
15A 07311 Screw with Washer 6
16 08383 Plunger Assy.,18mm (C,D,E)
For items 16A-16H 3
16 06622 Plunger Assy., 18mm, (F)
For items 16A-16H 3
16A 08384 Plunger Base 3
16B 08397 Plunger Pipe, 18mm 3
16C 07256 Centering Sleeve 3
16D 08399 Tensioning Screwing 3
16E 07023 O-Ring 3
ITEM PART DESCRIPTION QTY.
16F 07203 Backup Ring 3
16G 07258 Copper Washer (C,D,E) 3
16G 07676 Copper Washer (F) 3
16H 06431 Oil Scraper 3
17 06790 Crosshead Pin 3
19 08366 Oil Seal 3
20 06443 Seal Case 3
20A 06772 Gear Seal Adapter 3
21 07266 O-Ring 3
22 08059 O-Ring 3
23 08477 V-Sleeve, 18mm 6
24 07929 Pressure Ring 3
25 08402 Weep Return Ring 3
26 08409 Manifold (C) - Brass 1
26 08403 Manifold (D) - Bronze 1
26 08470 Aluminum Bronze (E) 1
26 06623 Manifold (F) 1
27A 06810 Valve Assy. 6
27 08404 Valve Seat 6
28 06809 Valve Plate 6
29 07906 Valve Spring 6
30 07907 Valve Spring Retainer 6
31 07770 O-Ring 6
32 06624 Plug (F) 6
32 08406 Plug (C,D,E) 6
33 06487 O-Ring (F) 6
33 07489 O-Ring (C,D,E) 6
34 08396 Cap Screw (C,D,E) 8
34 08484 Cap Screw (F) 8
36 12250 Plug, 1/2" BSP (E,F Only) 2
36A 06272 O-Ring (E,F Only) 2
37 07703 Plug, G 3/4" (C,D Only) 1
37A 07704 Copper Gasket (C,D Only) 1
P430, P440, P450 and P455 REPAIR KITS
Plunger Packing Kit - # 09141
Item Part # Description Qty
21 07266 O-Ring 3
22 08059 O-Ring 3
23 08477 V-Sleeve 6
24 07929 Pressure Ring 3
Optional Viton Seal Kit - #09456
Item Part # Description Qty
23 07902-0010 V-Sleeve 6
w/support ring, Viton
24 07904 Pressure Ring 6
Valve Assembly Kit - # 09142
Item Part # Description Qty
27A 06810 Valve Assembly, Complete 6
33 06487 O-Ring (P455 only) 6
33 07489 O-Ring (except P455) 6
Oil Seal Kit - #09306
Item Part # Description Qty
19 08366 Oil Seal 3
7
REPAIR INSTRUCTIONS - P430/P440, P450, AND P455
Note: Always take time to lubricate all metal and nonmetal parts with a light film of oil before reassembly. This step will ensure proper
fit, at the same time protecting the pump nonmetal parts (i.e., the elastomers) from cutting and scoring.
1) With a socket wrench,
remove the three discharge
valve plugs and three inlet
valve plugs (32). Inspect
the o-ring (33) for wear and
replace if damaged.
4) 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) Using needle nose pliers,
remove the inlet and discharge valve assemblies
(27A). Note: It may become
neccesary to remove the
valve seat (27) from the
valve casing using a
slidehammer.
5) Use a 8mm allen wrench to
remove the 8 socket head
cap screws (34). Carefully
slide the valve casing (26)
out over the plungers.
3) By inserting a small screw
driver between the valve seat
(27) and the valve spring retainer (30), the valve assembly can be separated.
6) Remove seal adaptors (20)
and weep return rings (25)
from the valve casing.
7) Remove the pressure rings
(24) and v-sleeves (23 Note: P422 & P423 pumps
have a support ring) from
the valve casing (26).
IMPORTANT! The grooved
seal (23) or respectively
grooved seal pack (23A) on
the high-pressure side is to be
fitted carefully into the valve
casing (26) using a screwdriver. Under no circumstances must the seal surface
in the valve casing or the seal
lip be damaged.
8) Remove the weep grooved
seal (23 or 23B) together
with pressure ring (24 _
P420 and P425 only) out
of the seal adaptor (20).
Check O-rings (21).
8
REPAIR INSTRUCTIONS - P430/P440, P450, AND P455
IMPORTANT! Care must be
taken that glue does not get
between the plunger pipe (16B)
and centring sleeve (16C). The
plunger pipe should not be
strained by eccentric tightening
of the tension screw or through
damage to front surface of
plunger, otherwise it is liable to
fracture.
9) Check surfaces of plunger
(16). Damaged surfaces
cause accelerated seal wear.
Deposits of all kinds must be
removed from the plungers.
IMPORTANT! Plunger
surfaces are not to be
damaged. If there are lime
deposits in the pump, care
must be taken that the dripreturn bore in parts (25)
and (26) ensure trouble-free
drip-return.
11) After installation of high
pressure seals (23 - Note:
P422 and P423, also have a
support ring), place seal
adaptor (20) with weep seals
& pressure ring installed,
weep return ring (25) and high
pressure weep return ring (24)
over plungers. 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 to the right).
10) If the plunger pipe (16B), or
oil seal (19) is worn, remove
tension screw (16D) and remove along with plunger
pipe (16B). Check and clean
plunger surface (16A), check
oil scraper (16H). Remove
the gear seal adapter (20A)
and, if necessary, replace oil
seals with seal lips facing
crankcase (1).Cover thread
of tension screw (16D) with
a thin film of Loctite and
tighten carefully to 26 ft.-lbs.
(35NM).
4
8
1
76
2
5
3
TORQUE SPECIFICATIONS - P430/P440, P450, AND P455
Position Item# Description U.S Metric
15A 07311 Screw with Washer 216 in.-lbs. 24.4 N-M
16D 08399 Tensioning Screw 240 in.-lbs. 27.1 N-M
32 06624 Plug (P455) 125 ft.-lbs. 169.4 N-M
32 08406 Plug (P430, P440, P450) 110 ft.-lbs. 149.1 N-M
34 08396/08484 Cap Screw 35 ft.-lbs. 47.5 N-M
Contact Giant Industries for service school information. Phone: (419) 531-4600
9
PUMP SYSTEM MALFUNCTION
MALFUNCTION CAUSE REMEDY
The Pressure and/ Worn packing seals Replace packing seals
or the Delivery Broken valve spring Replace spring
Drops Belt slippage Tighten or Replace belt
Worn or Damaged nozzle Replace nozzle
Fouled discharge valve Clean valve assembly
Fouled inlet strainer Clean strainer
Worn or Damaged hose Repair/Replace hose
Worn or Plugged relief valve on pump Clean, Reset, and Replace worn parts
Cavitation Check suction lines on inlet of
pump for restrictions
Unloader Check for proper operation
Water in crankcase High humidity Reduce oil change interval
Noisy Operation Worn bearings Replace bearings, Refill crankcase
Rough/Pulsating Worn packing Replace packing
Operation with Inlet restriction Check system for stoppage, air
Pressure Drop leaks, correctly sized inlet
Pump Pressure as Restricted discharge plumbing Re-size discharge plumbing to Flow
Rated, Pressure Rate of Pump
Drop at Gun
Excessive Worn plungers Replace plungers
Leakage Worn packing/seals Adjust or Replace packing seals
High Crankcase Wrong Grade of oil Giant oil is recommended
Temperature Improper amount of oil in crankcase Adjust oil level to proper amount
Worn seals Replace seals
oil with recommended lubricant
Cavitation Check inlet lines for restrictions
and/or proper sizing
plumbing to pump
Accumulator pressure Recharge/Replace accumulator
Unloader Check for proper operation
Cavitation Check inlet lines for restrictions
and/or proper size
Excessive vacuum Reduce suction vacuum
Cracked plungers Replace plungers
Inlet pressure too high Reduce inlet pressure
Preventative Maintenance Check-List & Recommended Spare Parts List
Check Daily Weekly 50hrs Every Every Every
Oil Level/Quality X
Oil Leaks X
W ater Leaks X
Belts, Pulley X
Plumbing X
Oil Change (1 Gallon) p/n 1154 X X
Seal Spare Parts (1 kit/pump) X
(See page 7 for kit list)
Oil Seal Kit (1 kit/pump) X
(See page 7 for kit lit)
Valve Spare Parts (1 kit/pump) X
(See page 7 for kit list)
500 hrs 1500 hrs 3000 hrs
Recommended Spare Parts
10
DIMENSIONS - P430, P440, P450 AND P455 - INCHES (MM)
11
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 NONSALINE, clean water applications.
2. One (1) year from the date of shipment for all other Giant industrial and consumer
pumps.
3. Six (6) months from the date of shipment for all rebuilt pumps.
4. 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 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 modifications made by the customer or third party.
6. 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
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 WARRANTIES 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.giantpumps.com
Copyright 2006 Giant Industries, Inc.
prior to the return to Giant Industries of all products under
12/06 P430_P440_P450_P455.PMD
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