Model
P46HT
Triplex Ceramic
Plunger Pump
Operating Instructions/
Repair and Service
Manual
Updated 3/98
Contents:
Installation Instructions: page 2
Pump Specifications: page 3
Exploded View: page 4
Kits/Torque Specs: page 4
Parts List: page 5
Trouble Shooting: page 6
Repair Instructions: page 7
Dimensions: back page
Warranty Information: back page
REPAIR INSTRUCTIONS - P46HT
1. To Check Suction and Discharge Valves
Loosen valve plugs (41 and 43) using a socket wrench. Note the arrangement for
reassembly and check the discharge valves underneath and suction valves (in
suction valve adapter 39).
2. To Check V-Sleeves
Separate valve casing (29) from the crankcase (1) and pull off over the plungers. If
the seals have to be replaced, remove all parts from the valve casing (29) in the
suction valve direction. Grease new v-sleeves (31) with grease before installing.
Examine the surfaces of the plunger pipes (24A) as damaged surfaces cause the
seals to wear out quickly.
3. To Check Plungers and Crankcase
If oil leaks at plunger outlet (22), and or the radial shaft seal (26), the worn plungers
and crosshead (plunger assembly) must be placed. Drain oil and remove crankcase cover (3) and valve casing (29). Take off bearing cover (12) and shaft protector (17) on one side before removing the crankshaft (18). Then remove crankshaft
axially by means of a press or a rubber hammer. Do not force the cranks on the
shaft when pulling through the connecting rod (20). Do not bend connecting rod.
Dismantle crosshead and connecting rod and replace worn parts.
Reinstall the crankshaft first being particularly careful with the cranks. Then press on
the bearing on both sides and finally install radial shaft seal and bearing cover.
4. To Replace Plunger Pipes
Screw out tension screw (24B), pull off plunger pipes (24A) and clean plunger
surface. Install new plunger pipe. Fix tension screw with screw-glue and tighten
carefully at 106 ft.-lbs.
5. Drip-Return
After the valve casing has been removed, the weep seals (50) in the intermediate
casing (46) can be examined and replaced as necessary. Should lime deposits
occur in the valve casing, care must be taken in keeping the two holes in the valve
casing (29) free to ensure trouble-free drip-return.
NOTE: Contact Giant Industries for Service School Information. Phone: (419)-531-4600
2
PUMP SYSTEM MALFUNCTION
MALFUNCTION
The Pressure and/or
the Delivery Drops
Water in crankcase
Noisy Operation
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
Unloader
High humidity
Worn seals
Worn bearings
Cavitation
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
pump for restrictions
Check for proper operation
Reduce oil change interval
Replace seals
Replace bearings, Refill crankcase
oil with recommended lubricant
Check inlet lines for restrictions
and/or proper sizing
Rough/Pulsating
Operation with
Pressure Drop
Pressure Drop at
Gun
Excessive Leakage
Worn packing
Inlet restriction
Accumulator pressure
Unloader
Cavitation
Restricted discharge plumbing
Worn plungers
Worn packing/seals
Excessive vacuum
Cracked plungers
Inlet pressure too high
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
High Crankcase
Temperature
Wrong Grade of oil
Improper amount of oil in crankcase
3
Giant oil is recommended
Adjust oil level to proper amount
Exploded View - P46HT
Valve Kit #09458
Qty. Part # Description
3 06018-0100 Valve Cage
3 06017-0100 Valve Spring
3 06016 Valve Plate
3 06014 Valve Seat
3 06015 O-Ring
P46HT TORQUE SPECIFICATIONS
Position Item# Description Torque Amount
24B 08456 Tension Screw, Plunger 108 in-lbs.
41 07235 Plug, Inlet 33-37 ft.-lbs.
43 07034 Plug, Outlet 32 ft.-lbs
P46HT REPAIR KITS
Seal Kit # 09514
Qty. Part # Description
3 11510 Spacer Sleeve
3 11511 Sleeve
4
P46HT PARTS LIST
ITEM PART DESCRIPTION QTY.
1 07222 Crankcase 1
2 07181 Vent/Filler Plug with Seal 1
3 08004 Cover, Crankcase 1
4 08005 O-Ring 1
5 08008 Oil Dipstick 1
6 01009 O-Ring 1
9 07188 Cylinder Screw with Slot 4
10 07223 Spring Washer 4
11 08012 Oil Drain Plug with Seal 1
11 A 08013 Gasket 1
12 07245 Bearing Cover 2
14 08015 Radial Shaft Seal 2
15 08020 Grooved Ball Bearing 2
16 07225 Hexagon Screw 1
17 07226 Shaft Protector 1
18 08022 Crankshaft 1
19 01024 Woodruff Key 1
20 08024 Connecting Rod 3
22 07201 Crosshead Assy. 3
23 01031 Crosshead Pin 3
24A 07021 Plunger Pipe 3
24B 08456 Tension Screw 3
24C 08457 Copper Screw 3
25 13333 Oil Scraper 3
26 07206 Radial Shaft Seal 3
26 A 11510 Spacer Sleeve 3
28 07207 Centering Sleeve 2
29 07033 Valve Casing 1
29 A 11502 Stud Bolt 2
30 07230 Pressure Ring 3
31 11511 Sleeve 3
32 07231 Support Ring 3
33 07232 Pressure Spring 3
34 06018-0100 Spring Tension Cap 6
35 06017-0100 Valve Spring 6
36 06016 V alve Plate 6
37 06014 Valve Seat 6
38 06015 O-Ring 6
39 07233 Suction Valve Adaptor 3
40 07234 O-Ring 3
41 07235 Plug 3
42 12004 O-Ring 3
43 07792 Plug 3
44 07035 O-Ring 3
45 07215 Stud Bolt 2
46 08040 Hex Nut 2
47 08041 Disc 2
48 07237 Intermediate Casing 1
49 07238 O-Ring 1
50 11512 Sleeve 6
51 07240 Support Ring 3
52 07109 Plug 1
53 13338 Plug 1
5
Model P46HT
TRIPLEX CERAMIC PLUNGER PUMP
Volume ........................................................................................................ Up to 127 GPH
Discharge Pressure .................................................................................... 900 PSI
Inlet Pressure .............................................................................................. 6 PSI minimum @ 194
.................................................................................................................... 15 PSI min. @ 194
Plunger Diameter ........................................................................................ 18mm
Crankcase Capacity.................................................................................... 8 fl. oz.
Temperature ................................................................................................ Up to 220
Inlet Ports ................................................................................................... (2) 1/2" BSP
Discharge Ports .......................................................................................... (2) 3/8" BSP
Pulley Mounting .......................................................................................... Either Side
Shaft Rotation ................................................................................ Top of pulley towards Head
Weight......................................................................................................... 14 lbs.
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.
1
o
F to 220o F
o
F
o
F
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.
P46HT PULLEY SELECTION AND HORSEPOWER REQUIREMENTS
PUMP MOTOR
1
GPH
RPM PULLY PULLY 500 PSI 700 PSI 900 PSI
71 500 7.75" 2.0" 0.41 0.57 0.73
106 750 7.75" 3.25" 0.61 0.84 1.09
HORSEPOWER INFORMATION
Horsepower ratings shown are the power requirements 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:
(GPH X PSI) / 87,375 = HP
127 900 7.75" 4.0" 0.72 1.02 1.31
1
GPH=Gallons per hour
6
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 220
0
F, it is important to
insure a positive head to the pump to prevent cavitation. (See chart below)
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
NPSHR(FT-HEAD)
RPM
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
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. Industrial Grade 90 wt. oil
may be used. 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.
NOTE: Contact Giant Industries for Service Information. Phone: (419) 531-4600.
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.
7
P46HT DIMENSIONS (INCHES)
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 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
manufacturers 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
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 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
Ó Copyright 1998 Giant Industries, Inc.
prior to the return to Giant Industries of all products
3/98 P46HT.PM6
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