View Manual - Giant Pumps
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1. 0 86 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 exten sion 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 The rating shown are the power 785 6 9 48 71 81 10 4 requirements forthe pump Gas 900 79 5 4 82 93 11 9 engine power outputs must be 1010 89 6 1 92 10 4 13 4 approximately twice the pump 1120 9 9 6 8 102 116 14 9 power requirements shown above 1450 We recommend a 1 15 service factor be specified when selecting an electric motor as the power source SPECIAL NOTE To compute specific pump horse power requirements use the following formula HP GPM X PSI 1450 The theoretical gallons per revolution gal rev is 0 0088 To find specific outputs at various RPM use the formula GPM 0 0088 x RPM P420CR 0020 PUMPS EXPLODED VIEW 15B 15C 16 08377 08378 06479 07186 08380 07109 07182 08092 01010 P420CR 0020 SPARE PARTS LIST DESCRIPTION Crankcase2. Worn packing seals Excessive vacuum Cracked plungers Inlet pressure too high Wrong Grade of oil Improper amount of oil in crankcase 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 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 Giant oil is recommended Adjust oil level to proper amount Preventative Maintenance Check List amp Recommended Spare Parts List Oil Level Quality aa o O l y Water Leaks xpo T SSS S Belts Puey x0 7 7 Pumin KO Recommended Spare Parts Oil Change 27 fl oz p n 1154 Seal Spare Parts 1 kit pump See page 5 for kit list Oil Seal Kit 1 kit pump See page 5 for kit list Valve Spare Parts 1 kit pump See page 5 for kit list P420CR 0020 Torque Specifications
3. Oil Fill Plug with Gasket Crankcase cover Oil Sight Glass w Gasket O Ring Oil Drain Plug Gasket for Oil Drain Plug Plug with Gasket Screw 01011 0400 Spring Washer 05290 05291 05292 05293 01016 07114 07459 05350 08475 08091 08390 05349 05348 05351 Bearing Cover Open Bearing Cover Closed Shim Shim May not be present O Ring Screw with Washer Radial Shaft Seal Taper Roller Bearing Crankshaft Fitting Key Connecting Rod Assembly Connecting Rod Screw Adapter Sleeve Plunger Assy 25mm For items 16A 16H W O O W po ND KR A QTY 1 ITEM PART 16A 05352 16B 08398 16D 08399 16E 07023 16F 07203 16G 07258 16H 06431 17 06790 19 05444 20 05443 21 07266 0001 23 12254 0020 23B 12255 0020 24 08376 25 08394 26 08395C 2 A 06406 27 08370 28 06791 0100 29 06377 0100 30 08372 31 07212 32 08373 33 07214 34 08396 DESCRIPTION Plunger Base Plunger Pipe 25mm Tensioning Screw O Ring Backup Ring Copper Washer Oil Scraper Crosshead Pin Oil Seal Seal Case O Ring Viton V Sleeve 25mm Teflon Weep Seal Teflon Pressure Ring Weep Return Ring Manifold Valve Assembly Valve Seat Valve Plate Valve Spring Valve Spring Retainer O Ring Plug O Ring Cap Screw QTY O O O O oO O O P420CR 0020 REPAIR KITS Valve Asse
4. Position ltem Description U S Metric 15B 05349 Screw with Washer 97 in lbs 11 NM 16D 08399 Tensioning Screw 22 ft lbs 30 NM 32 08373 Plug 107 ft Ibs 145 NM 34 08396 Cap Screw 30 ft Ibs 40 NM P420CR 0020 Dimensions Inch mm 2 3 56 5 6 5 165 2 0 50 2 5 Keywa 8x7 x 45mm ama 287 8 31 5 3 135 Between feet 4 1 108 6 0 158 5 IL 11 9 301 3 1 78 5 8 8 2225 Discharge 2 1 1 2x 3 4 BSP 0 27 3 5 89 2 6 67 1 6 40 835 2x 1 BSP 5 3 135 4x MIO 5 2 158 10 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 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
5. necessary Apply one drop of loctite 243 to the valve plugs 32 and tighten to 107 ft Ibs 145 NM 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 circum stances must the seal surface in the valve casing or the seal lip be damaged Remove the weep grooved seal 23B together with pressure ring 24 out of the seal adapter 20 Check O rings 21 7 g Remove the pressure rings 8 24 and v sleeves 23 from the valve casing 26 Repair Instructions P420CR 0020 Check surfaces of plunger 16 Damaged surfaces cause accelerated seal wear Deposits of all kinds must be removed from the plungers 11 If oil leaks under under the plunger 16 the oil seals 19 need to be replaced Remove oil plug 5 and drain oil With the valve casing 26 and seal case 20 removed ref instruc tions 5 8 6 and plunger disassembled ref 10 carefully pry out the oil seal with a flat screwdriver and replace it with a new one Make sure that the oil seal groove faces inward towards the oil NOTE Be careful not to score the crankcase guides where the oil seal sits and where the plunger base 16A moves through the crankcase 1 10 If the plunger pipe 16B is damaged or worn remove tension screw 16D and plunger pipe 16B Check and clean plunger surface 16A and check flinger 16H Cove
6. 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 5 and page 8 6 Before beginning operation of your pumping system remember Check that the crankcase and seal areas have been properly lubricated per recom mended 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 ina pump system has many advantages But ifitis used carelessly and without regard to its potential hazard it can cause serious i
7. L OTHER WARRAN TIES OR REPRESENTATION EXPRESS OR IMPLIED INCLUDING WITHOUT LIMITA TION ANY WARRANTIES OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE AND ALL SUCH WARRANTIES ARE HEREBY DISCLAIMED AND EX CLUDED BY THE MANUFACTURER GIANT INDUSTRIES INC 900 N Westwood Ave Toledo Ohio 43607 PHONE 419 531 4600 FAX 419 531 6836 www giantoumps com Copyright 2010 Giant Industries Inc 02 10 P400CR 0020 PMD
8. M e Triplex Ceramic Plunger Pump D 2 C R 2 Operating Instructions 4 0 00 0 Repair and Service Manual Machine Tool Coolant Pump Contents Installation Instructions page 2 Pump Specifications page 3 Exploded View page 4 Parts List Kits page 5 Repair Instructions pages 6 Trouble Shooting Chart page 8 Recommended Spare Parts List page 9 Torque Specs page 9 Dimensions page 10 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 informa tion 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
9. mbly Kit 09143 Plunger Packing Kit 09140 0021 Item Part Description Qty Item Part Description Qty 27A 08408 Valve Assembly Complete 6 al 07266 0001 O Ring Viton 3 33 07214 O Ring 6 23 12254 0020 V Sleeve Teflon 3 23B 12255 0020 Weep Seal Teflon 3 24 08376 Pressure Ring 6 Oil Seal Kit 09641 Item Part Description Qty 19 05444 Oil Seal 3 1 Repair Instructions P420CR 0020 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 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 Remove the o ring 31 2 3 Using needle nose pliers re move the inlet and discharge valve assemblies 2 Note It may become neccesary to remove the valve seat 27 from the valve casing using a slidehammer Use a 8mm allen wrench to 3 By inserting a small screw driver between the valve seat 27 and the valve spring re tainer 30 the valve assem bly can be separated 6 Remove seal adapters 20 and weep return rings 25 from the valve casing remove the 8 socket head cap screws 34 Carefully slide the valve casing 26 out over the plungers Inspect all parts for wear and replace as
10. njury P420 NPSHR Chart Special Conditions m mis J M e a a N manifold eee SCC eT 111111141 111 1 1111111 1 1 1 ol 200 400 600 800 1000 1200 1400 1500 RPM ER 1 1 1 6 I 4 6 IL k 6 4 6 A o 2 Li Q 5 amp gt This pump is designed to push away any leakage water to an external weep 1 8 BSP 2x 3 4 BSP port which is located onthe side of the For Machine Tool Coolant applications the liquid that comes from this area should be connected to the filter See picture at right Drain Weep Discharge P420CR Manifold 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 2 Pump operation must not exceed rated pressure volume that oil level is between the two lines on the oil dipstick or RPM A pressure relief device must be installed in the DO NOT OVERFILL discharge of the system Use SAE 80 90W or Giant s p n 01154 or ISO VG220 industrial gear lube oil 3 Acids alkalines or abrasive fluids cannot be pumped unless approval in writing is obtained before operation from Giant Industries Inc Crankcase oil should be changed after the first 50 hours of operation then a
11. of which the manufacturer s evaluation shows were defective at the time of shipment by the manufac turer The following items are NOT covered or will void the warranty Defects caused by negligence or fault of the buyer or third party Normal wear and tear to standard wear parts Use of repair parts other than those manufactured or authorized by Giant Improper use of the product as a component part Changes or modifications made by the customer or third party The operation of pumps and or accessories exceeding the specifications set forth in the Operations Manuals provided by Giant Industries Inc OO TO 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 prior to the return to Giant Industries of all products 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 AL
12. r thread of tension screw 16D witha thin film of Loctite and 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 tighten carefully to 22 ft lbs 30NM 12 After installation of high pressure seals 23 place seal case 20 with weep seals amp 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 30 ft los 40 NM in a crossing pattern as shown at right Contact Giant Industries for service school information Phone 419 531 4600 MALFUNCTION The Pressure and or the Delivery Drops Water in crankcase Noisy Operation Rough Pulsating Operation with Pressure Drop Pump Pressure as Rated Pressure Drop at Gun Excessive Leakage High Crankcase Temperature PUMP SYSTEM MALFUNCTION 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 Worn packing Inlet restriction Accumulator pressure Unloader Cavitation Restricted discharge plumbing Worn plungers
13. t regular intervals 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 Specifications Models P420CR 0020 U S Metric VOLUME 6 Up to 12 8 1 48 4 LPM Discharge Pressure cccsssccccsseeeceeeeeeeseees 1111 1 150 bar Inlet Pressure cccccsseeccceeeeeeeseeeeesaeeeeeseaes 4 35 to 145 PSI 3 to 10 bar SS 16 W DIA 24mm JB lz EEE T PENA E NCR Up to 1450 RPM Plunger Diameter c cccccsseecceeeeseeeeesesees 20 99 25mm Temperature of Pumped Fluids Up to 160 F 71 C 1 1 1 1 2 1 NPT 1 2 3 4 NPT SE FAO 172111610187777777 Top of pulley towards fluid end Crankshaft Diameter n Eel a 28mm Koy MIO oczek EA Ren AEC DOT 0 9 6 2 8mm Snan MOUN zs ee Either side WEIGNI swe ikea AERO GEARS 36 IDS GOZ 16 6 kg Crankcase Capacity ccccccsssseeeeeeeeeeeeees 27 1111 een 0 8 liters Volumetric Efficiency 1450 ee ee 0 95 Mechanical Efficiency 1450 4 4 9 5554995555 995
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