Giant P480 User manual

Models
P460A/P480/P414
Contents:
Installation Instructions: page 2
Pump Specications: page 3
Parts List/Torque Specs: page 4
Exploded View/Kits: page 5
Repassembly Instructions: page 6
Dimensions: page 7
Warranty Information back page
Triplex Ceramic
Plunger Pump
Operating Instructions/
Repair and Service Manual
Updated 02/12

Installation Instructions
4. 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
following a few guidelines available upon
request from Giant Industries, Inc. Required
horsepower for system operation can be ob-
tained from the charts on pages 3 through 5.
5. Before beginning operation of your pump-
ing system, remember: Check that the crank-
case 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
ow freely to the inlet of the pump.
1. The pump should be installed at on a base
to a maximum of a 15 degree angle of inclina-
tion to ensure optimum lubrication.
2. The inlet to the pump should be sized for
the ow rate of the pump with no unnecessary
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
1040F (400C,) 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.
IMPORTANT OPERATING CONDITIONS
Failure to comply with any of these conditions invalidates the warranty.
NOTE: Contact Giant Industries for Service School Information. Phone: [phone]
2
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 out-
line for installation. If you have unique requirements, please contact Giant Industries, Inc. or your
local distributor for assistance.
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 80-90 Industrial Gear Lube Oil (Gi-
ant’s P/N 01154)
Crankcase oil should be changed after
the rst 50 hours of operation, then at regular
intervals of 200 hours or less depending on
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 uids 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 tempera-
tures.
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.

Pump Specications
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.
Common Specications:
US Metric
3
Horsepower Ratings:
We recommend a 1.15 service factor be specied when selecting an electric motor as the power source.
To compute electric motor horsepower required, use the following formula: HP = (GPM X PSI) / 1450.
The formula to determine the horsepower required for a gas engine is: HP = (GPM X PSI) / 1150.
The formula to determine the horsepower required for a diesel engine is: HP = (GPM X PSI) / 1250.
For the Application of a Hydraulic Motor:
To Determine the Torque of a Hydraulic Motor -- (GPM x PSI x 36.77) / RPM = Torque (in-lbs)
Calculating RPM / GPM of Pump:
A pump must be connected to an electric motor or gas or diesel engine with the correct ratio of pulleys
and belts to attain the required speed and GPM. The use of a Variable Frequency Drive (VFD) may also
be used to control the RPM of a properly sized electric motor when variable ows are required.
(Max. Pump RPM / Rated Pump GPM) x Required Pump GPM = Required Pump RPM
To calculate a pulley diameter one (1) pulley diameter and the required pump RPM must be known:
(Pump RPM x Pump Pulley Diameter) / Motor RPM = Motor Pulley Diameter
(Motor RPM x Motor Pulley Diameter) / Pump RPM = Pump Pulley Diameter
Inlet Pressure .......................-4.35 to 145 PSI.... -0.3 to 10 Bar
Max. Temp. ...........................104 oF ................................. 40oC
Inlet Ports ............................................................. (2) 1/2” BSP
Discharge Ports .................................................... (2) 3/8” BSP
Shaft Rotation...........................Top of pulley towards uid end
Crankshaft Diameter....................................................... 28mm
Key Width ......................................................................... 8mm
Shaft Mounting ....................................................... Either side1
Weight ..................................46 lbs. ............................... 21 kg
Crankcase Capacity .............30 .oz......................... 0.9 Liters
1NOTES:
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 instruc-
tions as necessary for the proper as-
sembly sequence.
U.S. Measurements
Max. Flow Max. Discharge Pressure Max. Speed Power Req'd. Plunger Diameter Stroke Gallons per Rev.
Model GPM PSI RPM BHP in in gal/rev
P414 3.1 10,150 1450 21.7 0.55 0.94 0.00214
P460 3.2 7250 1450 16 0.55 0.94 0.00221
P480 3.8 7250 1450 19 0.55 0.94 0.00262
Metric Measurements
Max. Flow Max Discharge Pressure Max. Speed Power Req'd. Plunger Diameter Stroke Liters per Rev.
Model L/min Bar RPM kW mm mm L/rev
P414 11.8 700 1450 16.2 14 24 0.0081
P460 12.3 500 1450 11.9 14 24 0.00837
P480 14.5 500 1450 14.2 14 24 0.00992

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 Oil Drain Plug 1
5A 07182 Gasket for Oil Drain Plug 1
5B 08092 Plug with Gasket 1
6 01010 Screw 4
6A 01011-0400 Spring Washer 4
7 05290 Bearing Cover Open 1
8 05291 Bearing Cover Closed 1
8A 05292 Shim 1
8B 05293 Shim 1
9 01016 O-Ring 2
10 07114 Screw with Washer 8
11 07459 Radial Shaft Seal 1
12 05350 Bearing 2
13 08475 Crankshaft, P460 1
13 08482 Crankshaft, P480 1
14 08091 Fitting Key 1
15 08390 Connecting Rod Assy. 3
15A 07311 Screw with Washer 6
16 06480 Plunger Assy. 3
17 06790 Crosshead Pin 3
P460A/P480/P414 PARTS LIST
P460A/P480/P414 TORQUE SPECIFICATIONS
Item Part # Description Torque Amount
15A 07311 Screw with Washer 216 in.-lbs.
32 08406-0100 Plug 110 ft.-lbs.
34 06494 Cap Screw 36 ft.-lbs.
ITEM PART DESCRIPTION QTY.
19 05444 Oil Seal 3
20 05938 Seal Adapter 3
20A 06482 Seal Case 1
21 07266 O-Ring 3
23 06483 Grooved Seal Packing 6
23A 13036 Spacer Ring 3
24 06484 Pressure Ring 3
25 06485 Weep Return Ring 3
25A 06486 Support Ring 6
25B 06487 O-Ring 6
26 06488 Valve Casing (P460/P480) 1
26 05939 Valve Casing (P414) 1
27A 05543 Valve Assy. 6
(Includes items 27-31)
27 05541 Valve Seat 6
28 05542 Valve Plate 6
29 07906 Valve Spring 6
30 07907 Valve Spring Retainer 6
31 07770 O-Ring 6
32 08406-0100 Plug 3
33 07489 O-Ring 3
34 06494 Cap Screw 8
36 12256 Plug, 3/8” BSP 1
37 08486 Copper Washer 1
38 07109-0400 Plug, 1/2” BSP 1
39 06272 Copper Washer 1
4

Exploded View - P460A/P480
P460A/P480/P414 REPAIR KITS
Oil Seal Kit
Part # 09306
Item Part # Description Qty.
19 08366 Oil Seal 3
Plunger Packing Kits
Part # 09499
Item Part # Description Qty.
21 07266 O-Ring 3
23 06483 Grooved Seal Packing 6
23A 13036 Spacer Ring 3
24 06484 Pressure Ring 3
Valve Assembly Kits
Part # 09498
Item Part # Description Qty.
27A 05543 Valve Assembly, Complete 6
33 07489 O-Ring 3
5

Reassembly Instructions - P460A/P480/P414 PUMPS
Contact Giant Industries for service school information. Phone: [phone]
Inlet Valves
Remove inner hexagon screws (34) and pull off valve casing (26) to the front. Take out seal case (25) from valve
casing (26). Remove the exposed inlet valve with a pair of at nose pliers and the valve seat (27) with a valve
puller. Disassemble parts and examine valve plate (28), valve seat (27), O-ring (31) and support ring (31A). Re-
place worn parts. Tighten inner hexagon screws (34) again to 30 ft-lbs. (40Nm).
Discharge Valves: With a socket 32mm wrench, screw out valve plugs (32) . Remove the exposed discharge
valves with a pair of at nose pliers and the valve seat (27) with a valve seat puller. Disassemble parts and exam-
ine valve plate (28), valve seat (27), and O-rings (31, 33). Replace worn parts. Take care to reassemble in correct
sequence. Tighten plugs (32) to 110 ft-lbs. (150Nm).
Seals
Screw out oil drain plug (5) and drain oil. Remove inner hexagon screws (34) and pull off valve casing (26) front-
wise over the plungers (16).
Important! if the seal casing (20A) does not separate from the valve casing (26), press both casings apart by
placing two at screwdrivers in the side notches on the sal casing (20A). Be careful not to damage casing sur-
faces.
Remove seal cases (25) situated either in valve casing (26) or seal casing (20A). Separate seal casing (20A) from
seal retainers (20). Remove grooved ring (23) and guide ring (24) from the seal casing (20A). Examine O-rings
(25B) and support rings (25A) attached to seal casing (26). Check seal ring (23A) situated between valve casing
and seal casing, and replace if necessary. Then remove seal retainers (20) from crankcase (1). Pull grooved ring
(23) out of seal retainer (20). Check O-ring (21). Grease new seals and O-rings before reinstallation.
Important! Seal casing (20A) has a notched pin to ensure correct tting. Reassemble parts in the proper se-
quence.
Important! The grooved seal (23) on the high-pressure side is to be tted carefully into the seal casing (20A) us-
ing a 22mm plastic rod. Under no circumstances must the surface in the seal casing or the seal lip of the grooved
seal be damaged.
Check surfaces of plunger (16). Damaged surfaces cause hard wear on seals. Deposits of all kinds must be
removed from the plungers.
Important! The 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.
If the plunger (16) is worn, the complete plunger must be changed. The ceramic pipe alone cannot be changed
due to reasons of precision. When reassembling tighten inner hexagon screw (34) to 30 ft-lbs. (40 Nm).
If the plunger (16) is worn, the complete plunger must be changed. The ceramic pipe alone cannot be changed
due to reasons of precision. When reassembling tighten inner hexagon screw (34) to 30 ft-lbs (40Nm).
Gear and Plunger
If oil leaks where the plunger (16) protrudes out of the gear, gear seals (19) and plungers have to be examined
and replaced as necessary.
Gear Seal
Remove plug (5) and drain oil. Remove valve casing as described above. Take seal adapter (20) off plunger (16)
and replace gear seal (19).
Plungers
Drain oil and remove crankcase cover (3). Take off screws on con rods (15). Be careful not to mix up the con rod
halves. Push con rod shaft as far as possible into the crosshead guide. Loosen screws (10) and remove bearing
covers (7&8) with the help of a screw-driver.
Take crankshaft out carefully so as not to bend the con rods. Remove and dismantle con rods and plungers (18).
Replace worn parts.
To reinstall, insert con rods and plungers, put crankshaft in carefully and then push the bearing covers (7&8) onto
the ends of the crankshaft. Screw on bearing covers with screws (10). Mount con rod halves and tighten screws
(15) to 8 in-lbs. (11Nm). Mount crankcase cover (3) together with O-ring (4).
To rotate crankshaft to the opposite side.
The shaft end is on the left side of the pump looking at it from behind. If it should be on the other side, the valve
casing (26) and seal casing (20A) have to be removed, turned by 180o and then put on again. Turn seal adapt-
ers (20) 180o, so that the leakage holes are underneath. Oil dipstick (2) and oil drain plug (58) have to be inter-
changed and crankcase cover turned by 180o.
6

Model P460A/P480 Dimensions in(mm)
7

02/12 P460A.indd
GIANT INDUSTRIES, INC., 900 N. Westwood Ave., P.O. Box 3187, Toledo, Ohio 43607
PHONE [phone], FAX [phone], www.giantpumps.com
 Copyright 2012 Giant Industries, Inc.
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 dis-
charge manifolds are guaranteed for the life of the pump. 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 manufac-
turer’s evaluation shows were defective at the time of shipment by the manufacturer. The follow-
ing 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 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 prod-
ucts 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 pro-
vided 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 PURPOSE AND ALL
SUCH WARRANTIES ARE HEREBY DISCLAIMED AND EXCLUDED BY THE MANUFACTURER.