Giant P435b User manual

P435B

P455B Pumps

Triplex Ceramic

Plunger Pump

OperatingInstructions/

Repair and Service Manual

Contents:

Installation Instructions: page 2

Pump Specifications: pages 3,6

Exploded View: page 4

PartsList/Kits: page 5

Repair InstructionsTorque Specs.: pages 7-8

Trouble Shooting Chart: page 9

Recommended Spare Parts List: page 9

Dimensions: page 10

WarrantyInformation back page6/09

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

uniquerequirements,pleasecontactGiant

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

ensureoptimumlubrication.

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,

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.

4. Use of a dampener is necessary to minimize

pulsationatdriveelements,plumbing,connec-

tions, and other system areas. The use of a

dampener with Giant Industries, Inc. pumps is

optional,althoughrecommendedbyGiant

Industries, Inc. to further reduce system pulsa-

tion. Dampeners can also reduce the severity of

pressure spikes that occur in systems using a

shut-off gun. A dampener must be positioned

downstreamfromtheunloader.

5. Crankshaft rotation on Giant Industries, Inc.

pumps should be made in the direction desig-

nated by the arrows on the pump crankcase.

Reverse rotation may be safely achieved by

followingafewguidelinesavailableuponrequest

fromGiantIndustries,Inc.Requiredhorsepower

for system operation can be obtained from the

charts on page 3.

6. Beforebeginning operationofyourpumping

system, remember: Check that the crankcase

andsealareashavebeenproperlylubricatedper

recommendedschedules.Donot runthepump

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,rememberthathighpressureoperationinapumpsystemhasmanyadvantages. But,ifitisused

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 crank-

case so that oil level is between the two lines on

the oil dipstick. DO NOT OVERFILL.

UseSAE 80-90W or Giant’s p/n01154

Crankcaseoilshouldbe changed after the

first 50 hours of operation, then at regular inter-

valsof 500 hours or lessdependingon operating

conditions.

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

pumpedunless approvalinwritingis obtained

beforeoperationfrom Giant Industries, Inc.

4. Run the pump dry approximately 10 seconds

todrainthe water before exposure to freezing

temperatures.

INSTALLATION INSTRUCTIONS

Specifications

Model P455B

U.S.................................. (Metric)

Volume....................................................Up to 5.5 GPM................ (21.0 LPM)

Discharge Pressure Continuous ............Up to 4,350 PSI .............. (300 bar)

Discharge Pressure Intermittant* ...........Up to 5,100 PSI*............. (352 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" BSP

Discharge Ports .............................................................................. (2) 1/2" BSP

Shaft Rotation .........................................Top of pulley towards manifold

Crankshaft Diameter ..............................1.102”.............................. (28mm)

Key Width ................................................315”................................ (8mm)

ShaftMounting................................................................................. Either side1

Weight ....................................................37 lbs. 6oz ...................... (17.0 kg)

CrankcaseCapacity................................30 fl.oz. ........................... (0.89 liters)

Volumetric Efficiency @ 1450 ......................................................... (0.95)

Mechanical Efficiency @ 1450 ........................................................ (0.83)

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 ap-

proximately 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 0.00379.To find specific

outputs at various RPM, use the formula:

GPM = 0.00379 x RPM

RPM GPM 2000 PSI 3000 PSI 4350 PSI 5100 PSI*

920 3.5 4.8 7.2 10.5 12.3*

1050 4.0 5.5 8.3 12.0 14.1*

1185 4.5 6.2 9.3 13.5 15.8*

1315 5.0 6.9 10.3 15.0 17.6*

1450 5.5 7.6 11.4 16.5 19.3*

P455B HORSEPOWER

REQUIREMENTS

EXPLODED VIEW - P455

ITEM PART DESCRIPTION QTY.

1 08377 Crankcase 1

2 08378 Oil Fill Plug with Gasket 1

3 06479 Crankcasecover 1

3A 07186 Oil Sight Glass w/ Gasket 1

4 08380 O-Ring 1

5 07109 OilDrain Plug 1

5A 07182 Gasket for Oil Drain Plug 1

5B 08092 Plug with Gasket 1

6 01010 Screw 4

6A 01011-0400 SpringWasher 4

7 05290 BearingCoverOpen 1

8 05291 BearingCoverClosed 1

8A 05292 Shim 3

8B 05293 Shim (May not be present) 1

9 01016 O-Ring 2

10 07114 ScrewwithWasher 8

11 07459 RadialShaftSeal 1

12 05350 TaperRollerBearing 2

13 08475 Crankshaft(P435) 1

13 08482 Crankshaft(P455) 1

14 08091 Fitting Key 1

15 08390 ConnectingRodAssembly 3

16 05484 PlungerAssy.,18mm

(Items16A-16H) 3

16A 05352 PlungerBase 3

16B 08397 PlungerPipe,18mm 3

ITEM PART DESCRIPTION QTY.

16D 08399 TensioningScrewing 3

16E 07023 O-Ring 3

16F 07203 BackupRing 3

16G 07258 CopperWasher 3

16H 06431 OilScraper 3

17 06790 CrossheadPin 3

19 05444 Oil Seal 3

20 05534 SealCase 3

21 07266 O-Ring 3

23 08477 V-Sleeve,18mm 6

24 07929 PressureRing 3

25 08402 WeepReturnRing 3

26 05574 Manifold - Brass 1

27A 05543 Valve Assy. 6

27 05541 Valve Seat 6

28 05542 Valve Plate 6

29 07906 ValveSpring 6

30 07907 ValveSpringRetainer 6

31 07770 O-Ring 6

32 05544 Plug 6

33 05545 O-Ring 6

34 08484 CapScrew 8

36 13434 Plug, 1/2" BSP 1

36A 06272 O-Ring(P455Only) 1

37 07703 Plug, G 3/4" 1

P455B REPAIR KITS

Valve Assembly Kit - # 09644

Item Part #Description Qty

27A 05543 Valve Assembly, Complete 6

33 05545 O-Ring 6

Oil Seal Kit - #09641

Item Part # Description Qty

19 05444 Oil Seal 3

Plunger Packing Kit - # 09643

Item Part #Description Qty

21 07266 O-Ring 3

23 08477 V-Sleeve 6

24 07929 Pressure Ring 3

P455 SPARE PARTS LIST

Specifications

Model P435B

U.S.................................. (Metric)

Volume....................................................Up to 6.6 GPM................ (25.0 LPM)

Discharge Pressure Continuous ............Up to 3,625 PSI .............. (250 bar)

Inlet Pressure .........................................-4.35 to 145 PSI.............. (-.3 to 10 bar)

Stroke .....................................................0.94”................................ (24mm)