Giant P430A User manual

Contents:
Installation Instructions: page 2
Pump Specifications: pages 3-5
Exploded View: page 6
PartsList/Kits: page 7
Repair InstructionsTorque Specs.: pages 8-9
Trouble Shooting Chart: page 10
Recommended Spare Parts List: page 10
Dimensions: page 11
WarrantyInformation back page
Updated 12/06
P400 Series -
18mm Versions
Triplex Ceramic
Plunger Pump
OperatingInstructions/
Repair and Service Manual
For Models:
P430
P440
P450
P455

2
INSTALLATION INSTRUCTIONS
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.
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.
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 1600
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 shut-off gun.
Finally,rememberthathighpressureoperationinapumpsystemhasmanyadvantages. But,ifitisusedcarelessly
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.
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.
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 SAE 80-90W or Giant’s p/n 01154
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.

3
Specifications
Model P430A
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:
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 horse
power requirements, use the
following formula:
HP = (GPM X PSI) / 1450
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.
SPECIAL NOTE:
The theoretical gallons per revolution
(gal/rev) is 0.0046.
To find specific outputs at various RPM, use
the formula: GPM = 0.0046 x RPM
U.S...................................... (Metric)
Volume............................................................... Up to 6.7 GPM .................. (25.4 LPM)
Discharge Pressure Continuous ....................... Up to 3200 PSI.................. (220.6 bar)
Inlet Pressure...................................................... -4.35 to 145 PSI ................ (-.3 to 10 bar)
Stroke.................................................................. 0.945” ................................ (24mm)
RPM .................................................................................................................. Up to 1450 RPM
Plunger Diameter............................................... 0.708” ................................ (18mm)
Temperature of Pumped Fluids........................ Up to 160 oF ...................... (71 oC)
Inlet Ports ......................................................................................................... (2) 3/4" NPT
Discharge Ports................................................................................................ (2) 3/4" NPT
Shaft Rotation .................................................... Top of pulley towards manifold
Crankshaft Diameter ......................................... 1.102” ................................ (28mm)
Key Width .......................................................... .315” .................................. (8mm)
Shaft Mounting ................................................................................................ Either side1
Weight ................................................................ 36 lbs. 11oz ....................... (16.64 kg)
CrankcaseCapacity............................................ 30 fl.oz............................... (0.89 liters)
Volumetric Efficiency @ 1450 ...................................................................... (0.95)
Mechanical Efficiency @ 1450...................................................................... (0.83)
P430 HORSEPOWER
REQUIREMENTS
RPM GPM 1000
PSI 2000 PSI 3000 PSI 3200 PSI
920 4.8 3.3 6.6 9.9 10.6
1050 5.4 3.7 7.4 11.2 11.9
1185 6.1 4.2 8.4 12.6 13.5
1315 6.8 4.7 9.4 14.1 15.0
1450 7.5 5.2 10.3 15.5 16.6
6.7

P440 HORSEPOWER
REQUIREMENTS
RPM GPM 1000
PSI 2000 PSI 3000 PSI 4000 PSI
920 3.5 2.4 4.9 7.3 9.7
1050 4.0 2.8 5.5 8.3 11.1
1185 4.5 3.1 6.3 9.4 12.5
1315 5.0 3.5 6.9 10.4 13.9
1450 5.5 3.8 7.7 11.5 15.3
4
Specifications
Model P440A
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
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:
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 horse
power requirements, use the
following formula:
HP = (GPM X PSI) / 1450
SPECIAL NOTE:
The theoretical gallons per revolution
(gal/rev) is 0.00383.
To find specific outputs at various RPM,use
the formula: GPM = 0.00383 x RPM
U.S...................................... (Metric)
Volume............................................................... Up to 5.5 GPM .................. (20.8 LPM)
Discharge Pressure Continuous ....................... Up to 4000 PSI.................. (275.3 bar)
Inlet Pressure...................................................... -4.35 to 145 PSI ................ (-.3 to 10 bar)
Stroke.................................................................. 0.787” ................................ (20mm)
RPM .................................................................................................................. Up to 1450 RPM
Plunger Diameter............................................... 0.708” ................................ (18mm)
Temperature of Pumped Fluids........................ Up to 160 oF ...................... (71 oC)
Inlet Ports ......................................................................................................... (2) 3/4" NPT
Discharge Ports................................................................................................ (2) 3/4" NPT
Shaft Rotation .................................................... Top of pulley towards manifold
Crankshaft Diameter ......................................... 1.102” ................................ (28mm)
Key Width .......................................................... .315” .................................. (8mm)
Shaft Mounting ................................................................................................ Either side1
Weight ................................................................ 36 lbs. 11oz ....................... (16.64 kg)
CrankcaseCapacity............................................ 30 fl.oz............................... (0.89 liters)
Volumetric Efficiency @ 1450 ...................................................................... (0.95)
Mechanical Efficiency @ 1450...................................................................... (0.82)

5
P450/P455 HORSEPOWER
REQUIREMENTS
RPM GPM 2000
PSI 3000 PSI 4000 PSI 5000 PSI
800 3.0 4.2 6.3 8.4 10.5
933 3.5 4.9 7.3 9.8 12.2
1066 4.0 5.6 8.4 11.1 13.9
1200 4.5 6.3 9.4 12.5 15.7
1450 5.5 7.6 11.4 15.2 18.9
Specifications
Model P450A/P455
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.
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.
SPECIAL NOTE:
The theoretical gallons per revolution
(gal/rev) is 0.00379.
To find specific outputs at various RPM,
use the formula: GPM = 0.00379 x RPM
HORSEPOWER RATINGS:
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 horse
power requirements, use the
following formula:
HP = (GPM X PSI) / 1450
U.S...................................... (Metric)
Volume............................................................... Up to 5.5 GPM .................. (20.8 LPM)
Discharge Pressure Continuous ....................... Up to 5000 PSI.................. (344.7 bar)
Inlet Pressure...................................................... 90 PSI................................. (6.2 bar)
Stroke.................................................................. 0.787” ................................ (20mm)
RPM .................................................................................................................. Up to 1450 RPM
Plunger Diameter............................................... 0.708” ................................ (18mm)
Temperature of Pumped Fluids........................ Up to 160 oF ...................... (71 oC)
Inlet Ports ......................................................................................................... (2) 1/2" BSP
Discharge Ports................................................................................................ (2) 1/2" BSP
Shaft Rotation .................................................... Top of pulley towards manifold
Crankshaft Diameter ......................................... 1.102” ................................ (28mm)
Key Width .......................................................... .315” .................................. (8mm)
Shaft Mounting ................................................................................................ Either side1
Weight ................................................................ 36 lbs. 11oz ....................... (16.64 kg)
CrankcaseCapacity............................................ 30 fl.oz............................... (0.89 liters)
Volumetric Efficiency @ 1450 ...................................................................... (0.92)
Mechanical Efficiency @ 1450...................................................................... (0.86)

EXPLODED VIEW - P430/P440, P450, AND P455 PUMPS
6

7
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 07606 Oil Drain Plug 1
5A 07182 Gasket for Oil Drain Plug 1
5B 08092 Plug with Gasket 1
6 01010 Screw 4
6A 01011 Spring Washer 4
7 08471 Bearing Cover Open 1
8 08472 Bearing Cover Closed 1
8A 06245 Shim 1
8B 06330 Shim (May not be present) 1
9 01016 O-Ring 2
10 07114 ScrewwithWasher 8
11 07459 Radial Shaft Seal 1
12 08473 Bearing 1
12A 08474 Bearing 1
13 08475 Crankshaft (C) 1
13 08482 Crankshaft(D,E,F) 1
14 08091 Fitting Key 1
15 08390 Connecting Rod Assembly 3
15A 07311 ScrewwithWasher 6
16 08383 PlungerAssy.,18mm(C,D,E)
For items 16A-16H 3
16 06622 PlungerAssy.,18mm,(F)
For items 16A-16H 3
16A 08384 Plunger Base 3
16B 08397 Plunger Pipe, 18mm 3
16C 07256 Centering Sleeve 3
16D 08399 Tensioning Screwing 3
16E 07023 O-Ring 3
ITEM PART DESCRIPTION QTY.
16F 07203 Backup Ring 3
16G 07258 CopperWasher(C,D,E) 3
16G 07676 CopperWasher(F) 3
16H 06431 OilScraper 3
17 06790 Crosshead Pin 3
19 08366 Oil Seal 3
20 06443 Seal Case 3
20A 06772 Gear Seal Adapter 3
21 07266 O-Ring 3
22 08059 O-Ring 3
23 08477 V-Sleeve,18mm 6
24 07929 Pressure Ring 3
25 08402 Weep Return Ring 3
26 08409 Manifold (C) - Brass 1
26 08403 Manifold (D) - Bronze 1
26 08470 Aluminum Bronze (E) 1
26 06623 Manifold (F) 1
27A 06810 ValveAssy. 6
27 08404 Valve Seat 6
28 06809 Valve Plate 6
29 07906 Valve Spring 6
30 07907 Valve Spring Retainer 6
31 07770 O-Ring 6
32 06624 Plug(F) 6
32 08406 Plug(C,D,E) 6
33 06487 O-Ring(F) 6
33 07489 O-Ring(C,D,E) 6
34 08396 CapScrew(C,D,E) 8
34 08484 CapScrew(F) 8
36 12250 Plug, 1/2" BSP (E,F Only) 2
36A 06272 O-Ring(E,FOnly) 2
37 07703 Plug, G 3/4" (C,D Only) 1
37A 07704 Copper Gasket (C,D Only) 1
P430, P440, P450 and P455 SPARE PARTS LIST
C = P430 D=P440 E=P450 F=P455
P430, P440, P450 and P455 REPAIR KITS
Valve Assembly Kit - # 09142
Item Part # Description Qty
27A 06810 Valve Assembly, Complete 6
33 06487 O-Ring (P455 only) 6
33 07489 O-Ring (except P455) 6
Oil Seal Kit - #09306
Item Part # Description Qty
19 08366 Oil Seal 3
Plunger Packing Kit - # 09141
Item Part # Description Qty
21 07266 O-Ring 3
22 08059 O-Ring 3
23 08477 V-Sleeve 6
24 07929 Pressure Ring 3
Optional Viton Seal Kit - #09456
Item Part # Description Qty
23 07902-0010 V-Sleeve 6
w/support ring, Viton
24 07904 Pressure Ring 6

8
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.
2) Using needle nose pliers,
remove the inlet and dis-
charge valve assemblies
(27A). Note:It maybecome
neccesary to remove the
valve seat (27) from the
valve casing using a
slidehammer.
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.
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 ft. lbs.
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.
6) Remove seal adaptors (20)
and weep return rings (25)
from the valve casing.
7) Remove the pressure rings
(24) and v-sleeves (23 -
Note: P422 & P423 pumps
have a support ring) from
the valve casing (26).
8) Remove the weep grooved
seal (23 or 23B) together
with pressure ring (24 _
P420 and P425 only) out
of the seal adaptor (20).
Check O-rings (21).
IMPORTANT! The grooved
seal (23) or respectively
grooved seal pack (23A) on
the high-pressure side is to be
fitted carefully into the valve
casing (26) using a screw-
driver. Under no circum-
stances must the seal surface
in the valve casing or the seal
lip be damaged.
REPAIR INSTRUCTIONS - P430/P440, P450, AND P455
Note:Alwaystaketimetolubricateallmetalandnonmetalpartswithalightfilmofoilbeforereassembly. Thisstepwillensureproper
fit, at the same time protecting the pump nonmetal parts (i.e., the elastomers) from cutting and scoring.

9
Contact Giant Industries for service school information. Phone: [phone]
11) After installation of high
pressure seals (23 - Note:
P422 and P423, also have a
support ring), place seal
adaptor (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 35 ft.-lbs. in a
crossing pattern
(as shown to the right).
8
76
5
42
13
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.
10) If the plunger pipe (16B), or
oil seal (19) is worn, remove
tension screw (16D) and re-
move along with plunger
pipe (16B). Check and clean
plungersurface(16A),check
oil scraper (16H). Remove
the gear seal adapter (20A)
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
tightencarefullyto26 ft.-lbs.
(35NM).
IMPORTANT! Care must be
taken that glue does not get
between the plunger pipe (16B)
and centring sleeve (16C). 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.
Position Item# Description U.S Metric
15A 07311 Screw with Washer 216 in.-lbs. 24.4 N-M
16D 08399 Tensioning Screw 240 in.-lbs. 27.1 N-M
32 06624 Plug (P455) 125 ft.-lbs. 169.4 N-M
32 08406 Plug (P430, P440, P450) 110 ft.-lbs. 149.1 N-M
34 08396/08484 Cap Screw 35 ft.-lbs. 47.5 N-M
TORQUE SPECIFICATIONS - P430/P440, P450, AND P455
REPAIR INSTRUCTIONS - P430/P440, P450, AND P455

10
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
Preventative Maintenance Check-List & Recommended Spare Parts List
Check Daily Weekly 50hrs Every Every Every
500 hrs 1500 hrs 3000 hrs
OilLevel/Quality X
OilLeaks X
Water Leaks X
Belts,Pulley X
Plumbing X
RecommendedSpareParts
OilChange (1 Gallon) p/n1154 X X
Seal Spare Parts (1 kit/pump) X
(See page 7 for kit list)
Oil Seal Kit (1 kit/pump) X
(See page 7 for kit lit)
Valve Spare Parts (1 kit/pump) X
(See page 7 for kit list)

11
DIMENSIONS - P430, P440, P450 AND P455 - INCHES (MM)

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.
Ourotherpumpparts,usedin portable pressurewashersandincarwashapplications,
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.
Thiswarrantyislimitedtorepairorreplacementofpumpsandaccessoriesofwhichthe 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
workmanshiporfailureofmaterial. AReturnedGoodsAuthorization(R.G.A.)numberandcompleted
warranty evaluation form is required prior to the return to Giant Industries of all products under
warranty consideration. Call (419)-531-4600 or fax [phone] to obtain an R.G.A. number.
Repair or replacement of defective products as provided is the sole and exclusive remedy provided
hereunderandtheMANUFACTURER SHALLNOTBELIABLE FORFURTHERLOSS,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 WAR-
RANTIESORMERCHANTABILITYORFITNESSFORAPARTICULARPURPOSEANDALLSUCH
WARRANTIES ARE HEREBY DISCLAIMED AND EXCLUDED BY THE MANUFACTURER.
GIANT INDUSTRIES, INC., 900 N. Westwood Ave., P.O. Box 3187, Toledo, Ohio 43607
PHONE [phone], FAX [phone], www.giantpumps.com
 Copyright 2006 Giant Industries, Inc. 12/06P430_P440_P450_P455.PMD