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
1600F (P46W), 190oF (P46W-HK), or 220oF (P46HT) it is
important to insure a positive head to the pump to
prevent cavitation. See NPSHR curve for P46HT on
page 4.
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 3-4.
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 Giant synthetic or SAE 90 Gear Oil
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
Crankcase oil should be changed after the first 50 hours
temperatures.
of operation, then at regular intervals of 500 hours or
less depending on operating conditions.
2
Page 3
I
745
2.0
1.4
2.1
2.3
3.0
910
2.5
1.7
2.6
2.9
3.8
1140
3.1
2.1
3.2
3.6
4.7
3.6
2.5
3.7
4.2
5.4
3.9
2.7
4.0
4.5
5.9
Specifications
Model P46W/P46W-HK
Volume ........................................................................................................ Up to 3.9 GPM
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
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.
P46W & P46W-HK PULLEY SELECTION &
HORSEPOWER REQUIREMENTS
PUMP
PULLEY
7.75"3.55"
7.75"4.25"
7.75"5.25"
7.75"5.95"1305
7.75"6.45"1420
MOTOR
PULLEY
RPM GPM 1000 PSI 1500 PSI 1700 PSI 2200 PS
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) / 1460 = HP
3
Page 4
I
385
0.9
54.0
0.1
0.2
0.4
0.6
676
1.6
96.0
0.2
0.4
0.7
1.0
900
2.1
123
0.3
0.6
0.9
1.3
Specifications
Model P46HT
Volume ........................................................................................................ Up to 123 GPH (2.1 PGM)
Crankshaft .................................................................................................. 18 mm
23
20
16
13
o
F
10
6.6
3.3
NPSHR(FT-HEAD) Viscosity = 1 Centipoise
0
2004006008001000120014001600 1700
R
NPSHR Chart
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.
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.
P
M
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:
01061 - 7.75 Cast Iron 1 gr. - AB Section
01062 - 7.75 Cast Iron - 2 gr. - AB Section
01066 - 18 mm - 8 Steel Pulley - 1 gr.
Rails
01034 - Steel Box Rails
(L=9.25 x W=1.18 x H=1.62)
01075 - Plated Steel Channel Rails
(L=9.00 x W=2.12 x H=2.50)
5
Page 6
Exploded View - P46W, P46W-HK, P46HT
6
Page 7
P46W, P46W-HK & P46HT PARTS LIST
ITEMPARTDESCRIPTION QTY.
107222Crankcase1
207181Vent/Filler Plug with Seal1
2A07182G asket, Oil Filler Cap1
308004Cover, Crankcase1
408005O-Ring1
508008Oil D ip stick1
601009O-Ring1
907188Cylinder Screw with Slot4
1007223Spring Washer
(Excluding P46HT)4
1007223-0100 Spring Washer (P46HT only) 4
1108012Oil Drain Plug with Seal1
11A06709Gasket, Oil Drain Plug1
1207224Bearing Cover2
1408015Radial Shaft Seal2
1508020Ball Bearing2
1607225Screw and Washer6
1707226Shaft Protector1
1807227Crankshaft1
1901024Key1
2008024Connecting Rod3
2207201Crosshead Assy.3
2301031Crosshead Pin3
24A07021Plunger Pipe3
24B08456Tension Screw3
24C07676Copper Ring3
25*06648Flinger3
2607206Radial Shaft Seal3
26A11510Spacer Sleeve3
2807207Shi m, Manif old Stud2
2907033Manif old1
3007230Pressure Ring3
ITEMPARTDESCRIPTION QTY.
3207231Support Ring3
3307232Pressure Spring3
3407325Retainer, Spring
(P46W, & P46HT)6
3406018-0100 Retainer, Spring (P46HT)6
3506017-0100 Valve Spring6
3606016Valve Pl ate6
3706014Valve Seat6
3806015O-Ring6
3907233Suction Valve Adaptor3
4007234O-Ring, Adapter3
4107235Plu g Manifold (Inlet)3
4212004O-Ring, Manifold Plug (Inlet) 3
4307034Plug & O-Ring
(P46W & P46W-HK)3
4307792Plug & O-Ring (P46HT)3
4407035O-Ring for 433
4507215Stud, Manifold2
4608040Hex Nut, Manifold Stud2
4708041Spring Washer, Stud2
4807237Housing, Rear V-Sleeve1
4907238O-Ring, Rear
V-Sleeve Housing1
5007239Rear V-Sleeve (P46W only)3
5011512High Temperature Seal
(P46W-HK & P46HT)6
5107240Support Ring, Rear V-Sleeve 3
5207109Plug, 1/2 " BSP1
52A07110Gasket1
5313338Plug, 3/8 " BSP1
53A08486Copper Crush Washer
(P46W & P46W-HK)1
3107241V-Sleeve (P46W only)3
31A11511V-Sleeve, High Temp.
(P46W-HK, P46HT)3
* This will not fit into older P46W pumps with brass retainers (#08064). It can only be used with part number 11510 (#26A).
You can substitute p/n 13333 for 06648 only if the brass retainer (#08064) is used.
7
Page 8
PUMP SYSTEM MALFUNCTION
MALFUNCTIONCAUSEREMEDY
The Pressure and/Worn packing sealsReplace packing seals
or the DeliveryBroken valve springReplace spring
DropsBelt slippageTighten or Replace belt
Worn or Damaged nozzleReplace nozzle
Fouled discharge valveClean valve assembly
Fouled inlet strainerClean strainer
Worn or Damaged hoseRepair/Replace hose
Worn or Plugged relief valve on pumpClean, Reset, and Replace worn parts
CavitationCheck suction lines on inlet of
pump for restrictions
UnloaderCheck for proper operation
Water in crankcaseHigh humidityReduce oil change interval
Preventative Maintenance Check-List & Recommended Spare Parts List
CheckDailyWeekly50hrsEvery Every Every
500 hrs 1500 hrs 3000 hrs
Oil Level/QualityX
Oil LeaksX
Water LeaksX
Belts, PulleyX
PlumbingX
Recommended Spare Parts
Oil Change (1 Gallon) p/n 1154X X
Plunger Packing Kits (1 kit/pump) X
(See page 5 for kit list)
Valve Assembly Kit (1 kit/pump) X
(See page 5 for kit list)
Oil Seal Kit (1 kit/pump) X
(See page 5 for kit list)
8
Page 9
REPAIR INSTRUCTIONS - P46W, P46W-HK, P46HT
1. With a 22mm socket, remove the
three discharge (43) and three
inlet (41) manifold plugs. Check
o-rings (42 & 44) for wear and
replace as necessary.
4. Drain the oil from the pump.
Turn the pump over to remove
the two manifold stud nuts (46)
with a 17mm wrench.
2. Remove the discharge spring
retainer (34), valve spring (35),
and valve plate (36).
5. Tap the back of the manifold
(29) with a rubber mallet to
dislodge, and slide off the
pump.
3. Use a small slide hammer to
remove valve seats (37) from
manifold (29). Inspect valve
plates (36) and valve seats (37)
for wear. If excessive pitting is
seen, replace the worn parts.
Check valve seat o-ring (38) for
wear and replace as necessary.
6. From the front inlet valve ports,
remove the inlet valve assembly
(34-40).
343536403739
7. Inspect and clean the valve assembly parts. If pitted or worn, replace inlet
valve seats (37), valve plates (36), spring (35) and spring retainers (34).
Reinsert items 34-38 into valve adapter (39).
NOTE: Contact Giant Industries for Service School Information. Phone: (419)-531-4600
9
Page 10
REPAIR INSTRUCTIONS - P46W, P46W-HK, & P46HT
3031/5031A323833
8. The pressure rings (item 30) can now be removed by pulling straight out.
Inspect and clean manifold (29) and pressure ring. Replace if necessary.
From the front of the pump reinstall pressure rings into manifold (29) with
grooved side towards front of manifold. Install new v-sleeves (31 or 50), with
grooved sides towards front of pump. For P46W-HK & P46HT pumps, install
high temperature seal (31A) with grooved sides towards front of pump.
Replace the support rings (32) and pressure springs (33) into manifold (29).
Install valve assembly (34-40) into manifold (29). Reinstall manifold plugs
(43) and torque plugs to 52 ft.-lbs.
(P46W-HK & P46HT only)
24C
49
50
51
9. The rear V-sleeve housing (48)
may be removed by prying
evenly outward with a flat
screwdriver. After slipping
housing over plunger, inspect
seals (50) and O-ring (49) and
replace as necessary.
10. Inspect ceramic plunger (24A)
tips for wear. If necessary,
replacement of the ceramic
plungers may be accomplished
by removing the plunger bolt
assemblies (24B and 24C) with a
13mm wrench. Ceramic
plungers should now slide off
the stainless steel plunger base
(22). Excessive resistance to
plunger removal may be
overcome by heating the
stainless steel plunger base.
This will melt any excess loc-tite
beneath the ceramic plunger
allowing easy removal.
NOTE: Contact Giant Industries for Service School Information. Phone: (419)-531-4600
11. Replace copper ring (24C) onto
plunger bolt (24B). Slide
plunger bolt assembly into
ceramic plunger (24A). Apply a
light film of loc-tite to plunger
bolt threads and place plunger
assembly onto stainless steel
plunger base (22) and tighten to
105 in.-lbs.
12. To replace plunger oil seals
(26), proceed to Gear End
Disassembly section below.
Otherwise, continue as described below.
10
13. Before replacing pump manifold
(29), first rotate crankshaft (18)
until two outside plungers (24A)
extend evenly forward. Next
lubricate v-sleeves (50) in the rear
v-sleeve housing (48) and slide
housing over plungers. Lubricate
ceramic plungers with a light film
of oil. Carefully and evenly slide
manifold over plungers and press
manifold firmly against crankcase
(1). Replace manifold stud bolts
(45), washers (47) and nut (46) and
tighten to 35 ft.-lbs.
Page 11
REPAIR INSTRUCTIONS - P46W, P46W-HK, & P46HT
Gear End Disassembly
14. Remove the crankcase cover bolts (9). Inspect the crancase cover O-ring (4) for wear. Replace if necessary.
15. Inspect the dip stick (5) vent hole for signs of clogging. Clean if necessary.
16. To remove the crankshaft (18), first remove the bearing cover plates (12) Remove the key (19).
17. Hold the pump rear assembly with a wooden fixture, or other suitable device, in order to secure it while removing the
crankshaft (18). Using a plastic mallet, tap the crankshaft (18) from one side while turning it from the other side. The
turning insures that during this sequence the crankshaft does not become wedged agaisnt the connecting rods (20).
The far side bearing (15) will remain in the crancase (1). When free, the crankshaft (18) can be removed by hand.
18. The crankshaft bearing (15) remains on the crankshaft (18) as it is removed. The near side crankshaft seal (14) will be
removed by this procedure.
19. If necessary, use a bearing puller to remove crankshaft bearing (15).
20. Remove the connecting rod (20) and plunger rod/crosshead assembly (22) from the rear of the pump by pulling
straight out of the crosshead guides.
21. To remove the crankcase oil seal (26), tap oil seal out from the rear of the crankcase using a dowel and rubber mallet.
The area onto which the oil seal rests should be clean and dry. Put a small drop of loc-tite on the oil seals and place
into crankcase with clips facing the rear of the pump.
22. To remove the crosshead pin (23) from the crosshead (22), the assembly should be positioned on a wooden fixture to
avoid damage to crosshead. Drive out pin (23) on opposite side of mark on the crosshead. On those pumps without
mark on crosshead, drive out pin by tapping on tappered side of pin.
23. To remove the bearing remaining in the crankcase, insert small end of Giant Bearing tool and tap with a rubber mallet
untill bearing and seal are completely removed. The bearing can only be removed from the inside by inserting the Giant
Bearing Tool through the opposite side of the crankcase (1) and should be inspected for possible damage.
Gear End Reassembly
24. To reassemble, place the far bearing in the crankcase bearing housing and with the Giant Bearing tool as a driver, tap
into the crankcase (1) using a rubber mallet.
25. Insert the far side crankshaft oil seal (14) with the Giant Bearing Tool making sure it is firmly seated and well oiled.
Always make sure that the crankshaft seal (14) lip does not show signs of wear. Replace the bearing cover (12) and
tighten securely.
26. Replace the connecting rod (20) and plunger rod/crosshead assembly (22) by press-fitting the crosshead pin (23).
Make sure to insert the beveled edge of the crosshead pin into crosshead. If the crosshead has a mark, install pin
frommarked side. The crosshead pin (23) should not extend beyond either side of the crosshead in order to prevent
damage to the crosshead bore of the crankcase.
27. Place each crosshead/plunger assembly (22) into the pump making sure that all of the parts are well oiled before
insertion into the crankcase.
28. Replace near side bearing on crankshaft (18) and mallet to tap into place.
29. Take the crankshaft (18) end with the bearing and insert the other end through the bearing housing carefully threading
the lobes of the crankshaft through the well lubricated connecting rods (20). Turning the crankshaft while tapping it
through the connecting rods will help prevent binding and possiable damage to the connecting rods. Continue
tapping the crankshaft through the connecting rods (20) until it is firmly seated into far side bearing.
30. Insert the near side crankshaft oil seal (14), making sure it is firmly seated and well oiled. Replace the bearing cover (12)
and tighten securely.
31. See instructions (13 above) for re-installing fluid end onto gear end.
32. Clean the back edge of crankcase and replace the crankcase cover. Be careful not to pinch the crankcase cover o-ring.
33. Fill the P46W crankcase with 8 oz. of Giant oil. and check the oil level with the dipstick. Proper level is center of two
lines Reinstall the pump into your system.
11
Page 12
P46W, P46W-HK & P46HT DIMENSIONS
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:
willnever fail, period. If they ever fail, we will replace them free of charge. Our other
pumpparts, used in portable pressure washers and in car wash applications, are
warrantedfor five years from the date of shipment for all pumps used in NONSALINE, clean
1.For portable pressure washers and car wash applications, the discharge manifolds
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:
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.
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.
prior to the return to Giant Industries of all products
3/02 P46W, P46W-HK, & P46HT & P46HT.PM6
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