Giant P435-5100 User manual

Contents:
Installation Instructions: page 2
Specications: page3
Exploded View page 4
Parts List / Kits page 5
Repair Instructions: pages 6-8
Pump mounting selection Guide: page 9
Recommended Spare Parts List: page 9
Torque Specs: page 9
Trouble Shooting: page 10
Dimensions: page 11
Warranty Information back page
Triplex Ceramic Plunger Pump
Operating Instructions
Repair and Service Manual
Corrosion Resistant Pump
Pump Models
P435-5100 and P450-5100
updated 02/16

2
Installation Instructions
4. Use of a dampener is necessary to mini-
mize pulsation at drive elements, plumbing,
connections, and other system areas. The
use of a dampener with Giant Industries,
Inc. pumps is optional, although recom-
mended 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 direc-
tion designated by the arrows on the pump
crankcase. Reverse rotation may be safely
achieved by following a few guidelines avail-
able 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 pump-
ing system, remember: Check that
the crankcase and seal areas have been
properly lubricated per recommended sched-
ules. 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ow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 re-
quirements, please contact Giant Indus-
tries, Inc. or your local distributor for
assistance.
1.Thepumpshouldbeinstalledat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owrateofthepumpwithnounneces-
sary restrictions that can cause cavitation.
Teontapeshouldbeusedtosealalljoints.
If pumps are to be operated at temperatures
in excess of 160oF, 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ow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, 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.
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uidscan-
not be pumped unless approval in writing is
obtained before operation from Giant Indus-
tries, 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 crank-
case so that oil level is between the two lines on
the oil dipstick. DO NOT OVERFILL.
Use Giant Oil # 01154 or the equivalent
SAE 80W - 90 Industrial Gear oil
Crankcase oil should be changed after the
rst50hoursofoperation,thenatregularinter-
vals of 500 hours or less depending on operating
conditions.
NOTE: Contact Giant Industries for Service School Information. Phone: [phone]

3
Consult the factory for special requirements that must be met if the
pumpistooperatebeyondoneormoreofthelimitsspeciedabove.
U.S. (Metric)
Volume......................................................5.5 GPM .......................(20.8 l/m)
Discharge Pressure ..................................5075 PSI .......................(350bar)
Inlet Pressure............................................90 PSI ...........................(6.2 bar)
Stroke .......................................................0.79” ..............................20mm
RPM.................................................................................................Up to 1450 RPM
Plunger Diameter......................................0.71” ..............................18mm
Temperature of Pumped Fluids.................160o F ............................(70o C)
Inlet Ports.................................................. ......................................(2)3/4”BSP
Discharge Ports ...............................................................................(2) 1/2” BSP
Shaft Rotation..................................................................................Topofpulleytowardsuidend
Crankshaft Diameter........................................................................28mm
Key Width ........................................................................................8mm
Shaft Mounting.................................................................................Either side1
Weight.......................................................36.5lbs.........................(16.6 kg)
Crankcase Capacity..................................30.oz...........................(0.89 liters)
Model P450-5100 Specications
RPM GPM 2000 PSI 3000 PSI 4000 PSI 5000 PSI
800 3.0 4.1 6.2 8.3 10.3
933 3.5 4.8 7.2 9.7 12.1
1066 4.0 5.5 8.3 11.0 13.8
1200 4.5 6.2 9.3 12.4 15.5
1450 5.5 7.6 11.4 15.2 19.0
P450-5100
HORSEPOWER REQUIREMENTS
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 ll 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 en-
gine power outputs must be approxi-
mately twice the pump
power requirements shown above.
We recommend a 1.15 service
factorbespeciedwhenselecting
an electric motor as the power
source.Tocomputespecicpump
horsepower requirements, use the
following formula:
HP = (GPM X PSI) / 1450
SPECIAL NOTE:
The theoretical gallons per revolution
(gal/rev) is 0.00455.
TondspecicoutputsatvariousRPM,
use the formula: GPM = 0.00455 x RPM

4
P435-5100 and P450-5100 Exploded View

5
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 07109-0400 Oil Drain Plug 1
5A 07182 Gasket for Oil Drain Plug 1
5B 08092-0100 Plug with Gasket 1
6 01010-0100 Screw 4
6A 01011-0400 Spring Washer 12
7 05290 Bearing Cover, Open 1
8 05291 Bearing Cover, Closed 1
8A 05292 Shim 1
8B 05293 Shim(Maynotbepresent) 1
9 01016 O-Ring 2
10 07114-0100 Screw with Washer 8
11 07459 Radial Shaft Seal 1
12 05350 Bearing 2
13 08475 Crankshaft(P435-5100) 1
13 08482 Crankshaft(P450-5100) 1
14 08091 Fitting Key 1
15 08390 ConnectingRodAssembly 3
15B 05349 Screw 3
15C 05348 Washer 3
16 05575 PlungerAssy.Items16A-16G 3
16A 08384-0600 PlungerBase 3
16B 08397 PlungerPipe 3
P435-5100 and P450-5100 Parts List
ITEM PART DESCRIPTION QTY.
16D 08399-0100 TensioningScrew 3
16E 07023-0001 O-Ring 3
16F 07203 BackupRing 3
16G 07161-0100 CopperWasher 3
16H 06931 OilScraper 3
17 06790 CrossheadPin 3
19 05444 OilSeal 3
20 05534-0100 SealCase 3
21 07266 O-Ring 3
23 08477 V-Sleeve,18mm 6
24 07929 PressureRing 3
25 06804 WeepReturnRing 3
26 08470-5000 Manifold 1
27A 05578 Valve Assembly 6
27 05576 Valve Seat 6
28 05577 Valve Plate 6
29 07906-0100 Valve Spring 6
30 07907 ValveSpringRetainer 6
31 07770-0001 O-Ring 6
32 08406-0100 Plug 6
33 07489 O-Ring 6
34 08396-0100 CapScrew 8
36 12250 Plug,1/2”BSP 1
36A 06807 SteelRing 1
36B 13150-0100 Plug,3/4”,S.S. 1
36C 06808 SteelSealRing 1
Oil Seal Kit
# 09641
Item Part # Description Qty.
19 05444 OilSeal 3
Valve Assembly Kit
# 09646
Item Part # Description Qty.
27A 05578 Valve Ass’y, Complete 6
33 07489 O-Ring 6
Plunger Packing Kits
# 09141
Item Part # Description Qty.
21 07266 O-Ring 3
23 08477 V-Sleeve,18mm 6
24 07929 PressureRing 3
P435-5100 and P450-5100 Repair Kits

6
Consult the factory for special requirements that must be met if the
pumpistooperatebeyondoneormoreofthelimitsspeciedabove.
U.S. (Metric)
Volume......................................................6.6 GPM .......................(25.0 L/min)
Discharge Pressure ..................................3625PSI.......................(250 bar)
Inlet Pressure............................................90 PSI ...........................(6.2 bar)
Stroke .......................................................0.94” ..............................24 mm
RPM.................................................................................................Up to 1450 RPM
Plunger Diameter......................................0.71” ..............................18 mm
Temperature of Pumped Fluids.................160 oF ...........................(70 oC)
Inlet Ports.................................................. ......................................(2)3/4”BSP
Discharge Ports ...............................................................................(2) 1/2” BSP
Shaft Rotation..................................................................................Topofpulleytowardsuidend
Crankshaft Diameter........................................................................28 mm
Key Width ........................................................................................8 mm
Shaft Mounting.................................................................................Either side1
Weight.......................................................36.5lbs.........................(16.6 kg)
Crankcase Capacity..................................30.oz..........................(0.89 liters)
Model P435-5100 Specications
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 ll 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 en-
gine power outputs must be approxi-
mately twice the pump
power requirements shown above.
We recommend a 1.15 service
factorbespeciedwhenselecting
an electric motor as the power
source.Tocomputespecicpump
horsepower requirements, use the
following formula:
HP = (GPM X PSI) / 1450
SPECIAL NOTE:
The theoretical gallons per revolution
 (gal/rev)is0.00379.
TondspecicoutputsatvariousRPM,
usetheformula:GPM=0.00379xRPM
P435-5100 HORSEPOWER REQUIREMENTS
RPM GPM 2000
PSI
2500
PSI
3000
PSI
3625
PSI
920 4.2 5.8 7.2 8.7 10.5
1050 4.8 6.6 8.3 9.9 12.0
1185 5.4 7.4 9.3 11.2 13.5
1315 6.0 8.3 10.3 12.4 15.0
1450 6.6 9.1 11.4 13.7 16.5

7
Repair Instructions - P435-5100 and P450-5100
 Note:Alwaystaketimetolubricateallmetalandnonmetalpartswithalightlmofoilbeforereassembly.Thisstepwill
ensurepropert,atthesametimeprotectingthepumpnonmetalparts(i.e.,theelastomers)fromcuttingandscoring.
1) With a socket wrench,
remove the three dis-
charge valve plugs and
three inlet valve plugs
(32).Inspecttheo-ring
(33)forwearandreplace
if damaged.
2) Using needle nose pli-
ers, remove the inlet and
discharge valve assem-
blies (27A). Note: It may
become 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 retainer (30), the
valve assembly 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 lb-ft
(170 Nm)
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)fromthevalvecas-
ing (26).
8) Remove the weep
groovedseal(23)outof
the seal adaptor (20).
Check O-rings (21).
IMPORTANT! The grooved
seal(23)onthehigh-pressure
sideistobetted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.

8
REASSEMBLY INSTRUCTIONS - P435-5100 and P450-5100
ContactGiantIndustriesforserviceschoolinformation.
Phone:(419)531-4600
11) After installation of high
pressureseals(23),place
seal adapter (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rm-
ly. Replace the 8 socket
headcapscrews(34)and
tighten to 29.5 lb-ft (40 Nm)
in a crossing pattern (as
shown on the right).
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, re-
move tension screw (16D)
and remove along with
plunger pipe (16B). Check
and clean plunger surface
(16A), check oil scraper
(16H). Remove the seal
case (20) and, if necessary,
replace oil seals with seal
lips facing crankcase (1).
Cover thread of tension
screw (16D) with a thin
lm of Loctite and tighten
carefully to 221-265 in-lbs
(25-30NM).
IMPORTANT! Care must
be taken that glue does not
get between the plunger
pipe (16B) and plunger base
(16A). 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.
642 7
8135

9
Gear End
If oil leaks where the plunger (16) extends from the crankcase (1), the oil seals (19) and plungers (16)
must be examined and replaced if necessary. Remove oil plug (5) and drain oil; remove crankcase
cover(3).Removevalvecasing(26),andsealcase(20).Thenremoveplungerpipes(16B)andoil
scrapers (16H) as described above.
IMPORTANT Before removing conn-rods be aware of their position on the crankshaft so as to return
them to the same location when re-assembling.
Remove screws from connecting rods (15), separate the back conn-rod half from the crankshaft and
the front conn-rod half. The conn-rod halves must be kept as pairs - do not mix them up. Push conn-rod
shaft as far as possible into the crosshead guide. Remove screws (10) and pry bearing covers (7,8) off
gently with a screwdriver.
Carefullyremovecrankshaft(13)bythreadingitthroughtheconn-rods(15),makingsurenottobend
the conn-rods. Remove and disassemble conn-rods and plungers (16) paying close attention not to
damage the plungers. Pry out oil seal (19) using a screwdriver. Examine plunger surfaces (16A) and
replace if necessary.
Tore-assemble,rstpresstheoilseal(19)intothecrankcase.Theninsertconn-rodswithplungers
rememberingtheiroriginallocation.Threadinthecrankshaft(13).Replacebearingcover(7)andO-
ring(9)togetherwiththeradialshaftseal(11)androllerbearing(12)andxinplacewithscrews(10).
Replacerollerbearing(12),bearingcover(8)andO-ring(9).Adjusttheclearancebyttingshims(8A)
underthebearingcoverasrequiredtoensurethatthecrankshaft(13)turnseasilywithoutplaybeing
felt. Finally, mount conn-rod halves on crankshaft matching them with other half and tighten screws
(15)to97lb-in(11Nm).Replacecrankcasecover(3)ando-ring(4).Whenremountingthevalvecasing
(26),tightenhexagonsocketscrews(34)to29.5lb-ft(40Nm).
To Move Crankshaft to Opposite Side
Remove the valve casing (26) and seal case (20). Then rotate the crankcase 180°. Interchange the oil
plug((5B)withoildipstick(2).Rotatethecrankcasecover(3)180°.Remountthevalvecasingtogether
with the seal casing and the seal adapters (20). Make sure that the seal adapters are rotated in order
that the bores face downwards.
REASSEMBLY INSTRUCTIONS - P435-5100 and P450-5100

10
Pump Mounting Selection Guide
Bushings
07175 - 28 mm Tapered H Bushing
Pulley & Sheaves
01055 - 7.75” Cast Iron - 2 gr. - AB Section
01062 - 7.75” Cast Iron - 2 gr. - AB Section
Rails
07358 - Plated Steel Channel Rails
(L=9.18”xW=1.88”xH=3.00”)
Position Item# Description Torque Amount
15A N/A Screw with Washer 97 in-lbs (11 Nm)
 16D 08399-0100 TensioningScrew 221to265in-lbs(25-30Nm)
 32 08406-0100 Plug 125ft-lbs(170Nm)
 34 08396-0100 InnerHexagonScrew 29.5ft-lbs(40Nm)
P435-5100 and P450-5100 PUMP TORQUE SPECIFICATIONS
Preventative Maintenance Check List & Recommended Spare Parts List
Check Daily Weekly 50 hrs
Every
500 hrs
Every
1500 hrs
Every
3000 hrs
Oil Level/Quality X
Oil Leaks X
Water Leaks X
Belts, Pulley X
Plumbing X
Recommended Spare Parts
Oil Change p/n 01154 X X
Seal Spare Parts (1 kit/pump)
(see page 5 for kit list)
X
Oil Seal Kit (1 kit/pump)
(see page 5 for kit list)
X
Valve Spare Parts (1 kit/pump)
(see page 5 for kit list)
X

11
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,Rell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 Pres-
sure 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
Rated,Pressure  ow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

GIANT INDUSTRIES, INC.,900N.WestwoodAve.,Toledo,Ohio43607
PHONE(419)531-4600,FAX(419)531-6836,www.giantpumps.com
 Copyright 2016 Giant Industries, Inc. 02/16P435-5100_P450-5100.indd
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-serve 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ve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:
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modicationsmadebythecustomerorthirdparty.
 6. Theoperationofpumpsandoraccessoriesexceedingthespecications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 work-
manship 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 war-
ranty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 WAR-
RANTIES OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSEANDALL SUCH
WARRANTIES ARE HEREBY DISCLAIMED AND EXCLUDED BY THE MANUFACTURER.
P435-5100 and P450-5100 Pump Dimensions - Inches (mm)