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
(P46W), 195oF (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.
0
F
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. The open end shaft must
be covered by the shaft protector (17).
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
2. Pump operation must not exceed rated
pressure, volume, or RPM.
A pressure
relief device must be installed in the discharge of the system.
the oil dipstick. DO NOT OVERFILL.
3. Acids, alkalines, or abrasive fluids
Use Giant Oil # 01154 or the
equivalent SAE 80W - 90
Industrial Gear 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 condi-
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.
tions.
2
Specifications
Model P46W/P46W-HK
U.S. Metric
Volume............................................................................. Up to 3.9 GPM ...............14.7 L/M
Discharge Pressure ......................................................... 2200 PSI ........................ 150 bar
Inlet Pressure ...................................................................-4.35 to145 psi................-0.3 to 10 bar
Maximum Crankshaft Rotation Speed .......................................................................Up to 1420 RPM
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.
P46W / P46W-HK PULLEY SELECTION & HORSEPOWER
REQUIREM ENTS - EL ECTRIC M OTO R
PUMP
PULLEY
7.75"3.55"7452.01.42.12.33.0
7.75"4.25"9102.51.72.62.93.8
7.75"5.25"11403.12.13.23.64.7
7.75"5.95"13053.62.53.74.25.4
7.75"6.45"14203.92.74.04.55.9
MOTOR
PULLEY
RPMGP M1000 PS I 1500 PS I 1700 PS I 2200 PS I
HORSEPOWER INFORMATION
The ratings shown in the chart reflect the horsepower requirements for electric motors. We
recommend motors with a 1.15 service factor be
specified.
To compute specific pump horsepower requirements, use the following formula:
Pulley Mounting ............................................................................................................................ Either Side
Shaft Rotation ................................................................................ ...........................Top of pulley towards head
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.
HORSEPOWER INFORMATION
The ratings shown in the chart reflect the horsepower
requirements for electric motors. We recommend
motors with a 1.15 service factor be specified.
To compute specific pump horsepower requirements,
use the following formula:
* 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
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
Oil Level/QualityX
Oil LeaksX
Water LeaksX
Belts, PulleyX
PlumbingX
Oil Change (8 oz.) 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)
500 hrs 1500 hrs 3000 hrs
Recommended Spare Parts
8
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
REPAIR INSTRUCTIONS - P46W, P46W-HK, & P46HT
305031323833
(P46W-HK & P46HT only)
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), with grooved sides towards front of pump. For P46WHK & P46HT pumps, install high temperature seal (50) before v-sleeve
(31) 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.
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
rear v-sleeves (50), support
rings (51) 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 rear v-sleeves (50)
and support ring (51) 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.
REPAIR INSTRUCTIONS - P46W, P46W-HK, & P46HT
Gear End Disassembly
14. Remove the crankcase cover bolts (9). Inspect the crankcase 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
against the connecting rods (20). The far side bearing (15) will remain in the crankcase (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 tapered 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 from marked 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 use 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 possible 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.
11
P46W, P46W-HK & 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 NON-SALINE, 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:
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.
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 under