Pump Model
P450-5100
Corrosion Resistant Pump
Triplex Ceramic
Plunger Pump
Operating Instructions
Repair and Service Manual
07/09
Contents:
Installation Instructions: page 2
Specifications: page 3
Exploded View page 4
Parts List / Kits page 5
Repair Instructions: pages 6-8
Pump mounting selection
Guide: page 9
Recommended
Spare Parts List page 9
Torque Specs: page 9
Trouble Shooting: 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
0
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 shutoff 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 shutoff 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 chart on
page 3.
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 Giant Oil # 01154 or the equivalent
SAE 80W - 90 Industrial Gear oil
3. Acids, alkalines, or abrasive fluids
cannot be pumped unless approval in writing
Crankcase oil should be changed after the
first 50 hours of operation, then at regular inter-
is obtained before operation from Giant
Industries, Inc.
vals of 500 hours or less depending on operating
conditions.
4. Run the pump dry approximately 10
seconds to drain the water before exposure
to freezing temperatures.
NOTE: Contact Giant Industries for Service School Information. Phone: (419)-531-4600
2
Specifications
I
P450-5100
Model P450-5100
U.S. (Metric)
Volume .............................................................................5.5 GPM.................................. (20.8 l/m)
Discharge Pressure ................................................5075 PSI ................................. (350 bar)
Inlet Pressure ..............................................................90 PSI ....................................... (6.2 bar)
Stroke................................................................................ 0.79”........................................... 20mm
RP M ........................................................................................................................................... Up to 1450 RPM
Plunger Diameter.......................................................0.71” ........................................... 18mm
Temperature of Pumped Fluids .............................160
Inlet Ports ................................................................................................................................. (2) 3/4" BSP
Discharge Ports.................................................................................................................. (2) 1/2" BSP
Shaft Rotation ...................................................................................................................... Top of pulley towards fluid end
Crankshaft Diameter....................................................................................................... 28mm
Key Width ............................................................................................................................... 8mm
Shaft Mounting .................................................................................................................... Either side
Weight ...............................................................................36.5 lbs. ................................... (16.6 kg)
Crankcase Capacity ...............................................30fl.oz. ...................................... (0.89 liters)
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.
o
F ........................................ (70o C)
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 fill and the oil drain plugs,
also. Refer to the repair instructions as necessary for the proper assembly sequence.
HORSEPOWER RATINGS:
HORSEPOWER REQUIREMENTS
RP M GP M 2000 P SI 3000 PS I 4000 PS I 5000 PS
800 3.0 4.1 6.2 8.3 10.3
933 3.5 4.8 7.2 9.7 12.1
1066 4.0 5.5 8.3 11.0 13.8
1200 4.5 6.2 9.3 12.4 15.5
1450 5.5 7.6 11.4 15.2 19.0
The rating shown are the power
requirements 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 specified when selecting
an electric motor as the power
source. To compute specific pump
SPECIAL NOTE:
The theoretical gallons per revolution
(gal/rev) is 0.00379.
To find specific outputs at various RPM,
horsepower requirements, use the
following formula:
HP = (GPM X PSI) / 1450
use the formula: GPM = 0.00379 x RPM
3
P450-5100 Exploded View
4
P450-5100 PUMP 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 07109-0400 Oil Drain Plug 1
5A 07182 Gasket for Oil Drain Plug 1
5B 08092-0100 Plug with Gasket 1
6 01010-0100 Screw 4
6A 01011-0400 Spring Washer 12
7 05290 Bearing Cover, Open 1
8 05291 Bearing Cover, Closed 1
8A 05292 Shim 1
8B 05293 Shim (May not be present) 1
9 01016 O-Ring 2
10 07114-0100 Screw with Washer 8
11 07459 Radial Shaft Seal 1
12 05350 Bearing 2
13 08482 Crankshaft 1
14 08091 Fitting Key 1
15 08390 Connecting Rod Assembly 3
15B 05349 Screw 3
15C 05348 Washer 3
16 05575 Plunger Assy. Items 16A-16G 3
16A 08384-0600 Plunger Base 3
16B 08397 Plunger Pipe 3
ITEM PART DESCRIPTION QTY.
16D 08399-0100 Tensioning Screw 3
16 E 07023-0001 O-Ring 3
16F 07203 Backup Ring 3
1 6G 07161-0100 Copper Washer 3
16H 06931 Oil Scraper 3
17 06790 Crosshead Pin 3
19 05444 Oil Seal 3
20 05534-0100 Seal Case 3
21 07266 O-Ring 3
23 08477 V-Sleeve, 18mm 6
24 07929 Pressure Ring 3
25 06804 Weep Return Ring 3
26 08470-5000 Manifold 1
27A 05578 Valve Assembly 6
27 05576 Valve Seat 6
28 05577 Valve Plate 6
29 07906-0100 Valve Spring 6
30 07907 Valve Spring Retainer 6
31 07770-0001 O-Ring 6
32 08406-0100 Plug 6
33 07489 O-Ring 6
34 08396-0100 Cap Screw 8
36 12250 Plug, 1/2" BSP 1
36A 06807 Steel Ring 1
36B 13150-0100 Plug, 3/4”, S.S. 1
36C 06808 Steel Seal Ring 1
Plunger Packing Kits
# 09141
Item Part # Description Qty.
21 07266 O-Ring 3
23 08477 V-Sl eeve,18mm 6
24 07929 Pressure Ring 3
Repair Kits
Oil Seal Kit
# 09641
Item Part # Description Qty.
19 05444 Oil Seal 3
Valve Assembly Kit
# 09646
Item Part # Description Qty.
27A 05578 Valve Ass’y, Complete 6
33 07489 O-Ring 6
5
REPAIR INSTRUCTIONS - P450-5100
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 lb-ft (170
Nm)
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.
IMPORTANT! The grooved
seal (23) 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.
7) Remove the pressure
rings (24) and v-sleeves
(23) from the valve
casing (26).
8) Remove the weep
grooved seal (23) out of
the seal adaptor (20).
Check O-rings (21).
6
REASSEMBLY INSTRUCTIONS - P450-5100
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 drip-return
bore in parts (25) and
(26) ensure trouble-free
drip-return.
IMPORTANT! Care must be
taken that glue does not get
between the plunger pipe
(16B) and plunger base (16A).
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.
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 seal
case (20) 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 221265 in-lbs (25-30NM).
11) After installation of high
pressure seals (23), place
seal adapter (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 29.5 lb-ft
(40 Nm) in a crossing
pattern (as shown on the
right).
4
8
1
76
2
5
3
Contact Giant Industries for service school information. Phone: (419) 531-4600
7
Gear End
If oil leaks where the plunger (16) extends from the crankcase (1), the oil seals (19) and plungers (16) must be examined
and replaced if necessary. Remove oil plug (5) and drain oil; remove crankcase cover (3). Remove valve casing (26), and
seal case (20). Then remove plunger pipes (16B) and oil scrapers (16H) as described above.
IMPORTANT Before removing conn-rods be aware of their position on the crankshaft so as to return them to the same
location when re-assembling.
Remove screws from connecting rods (15), separate the back conn-rod half from the crankshaft and the front conn-rod half.
The conn-rod halves must be kept as pairs - do not mix them up. Push conn-rod shaft as far as possible into the crosshead
guide. Remove screws (10) and pry bearing covers (7,8) off gently with a screwdriver.
Carefully remove crankshaft (13) by threading it through the conn-rods (15), making sure not to bend the conn-rods. Remove
and disassemble conn-rods and plungers (16) paying close attention not to damage the plungers. Pry out oil seal (19) using
a screwdriver. Examine plunger surfaces (16A) and replace if necessary.
To re-assemble, first press the oil seal (19) into the crankcase. Then insert conn-rods with plungers remembering their
original location. Thread in the crankshaft (13). Replace bearing cover (7) and o-ring (9) together with the radial shaft seal
(11) and roller bearing (12) and fix in place with screws (10). Replace roller bearing (12), bearing cover (8) and o-ring (9).
Adjust the clearance by fitting shims (8A) under the bearing cover as required to ensure that the crankshaft (13) turns easily
without play being felt. Finally, mount conn-rod halves on crankshaft matching them with other half and tighten screws (15)
to 97 lb-in (11 Nm). Replace crankcase cover (3) and o-ring (4). When remounting the valve casing (26), tighten hexagon
socket screws (34) to 29.5 lb-ft (40 Nm).
To Move Crankshaft to Opposite Side
Remove the valve casing (26) and seal case (20). Then rotate the crankcase 180°. Interchange the oil plug ((5B) with oil
dipstick (2). Rotate the crankcase cover (3) 180°. Remount the valve casing together with the seal casing and the seal
adapters (20). Make sure that the seal adapters are rotated in order that the bores face downwards.
8
Preventative Maintenance Check-List & Recommended Spare Parts List
Check Daily Weekly 50hrs Every Every Every
500 hrs 1500 hrs 3000 hrs
Oil Level/Quality X
Oil Leaks X
Water Leaks X
Belts, Pulley X
Plumbing X
Recommended Spare Parts
Oil Change X X
Seal Spare Parts (1 kit/pump) X
(See page 5 for kit list)
Oil Seal Kit (1 kit/pump) X
(See page 5 for kit lit)
Valve Spare Parts (1 kit/pump) X
(See page 5 for kit list)
P450-5100 PUMP TORQUE SPECIFICATIONS
Position Item# Description Torque Amount
15A N/A Screw with Washer 97 lb-in (11 Nm)
16D 08399-0100 Tensioning Screw 221 to 265 lb-in
(25-30 Nm)
32 08406-0100 Plug 125 lb-ft (170 Nm)
34 08396-0100 Inner Hexagon Screw 29.5 lb-ft (40 Nm)
Pump Mounting Selection Guide
Bushings
07175 - 28 mm Tapered H Bushing
Pulley & Sheaves
01055 - 7.75” Cast Iron - 2 gr. - AB Section
01062 - 7.75” Cast Iron - 2 gr. - AB Section
Rails
07358 - Plated Steel Channel Rails
(L=9.18”x W=1.88”x H=3.00”)
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
Worn seals Replace seals
Noisy Operation Worn bearings Replace bearings, Refill crankcase
oil with recommended lubricant
Cavitation Check inlet lines for restrictions
and/or proper sizing
Rough/Pulsating Worn packing Replace packing
Operation with Inlet restriction Check system for stoppage, air
Pressure Drop leaks, correctly sized inlet
plumbing to pump
Accumulator pressure Recharge/Replace accumulator
Unloader Check for proper operation
Cavitation Check inlet lines for restrictions
and/or proper size
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
Excessive vacuum Reduce suction vacuum
Cracked plungers Replace plungers
Inlet pressure too high Reduce inlet pressure
High Crankcase Wrong Grade of oil Giant oil is recommended
Temperature Improper amount of oil in crankcase Adjust oil level to proper amount
10
P450-5100 PUMP DIMENSIONS - 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.
prior to the return to Giant Industries of all products under
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., Toledo, Ohio 43607
PHONE (419) 531-4600, FAX (419) 531-6836, www.giantpumps.com
© Copyright 2009 Giant Industries, Inc.
7/09 P450-5100.PMD
Loading...