Triplex Ceramic
Plunger Pump
Operating Instructions/
Repair and Service
Manual
Models
P420A-3100
& P420A-5100
Corrossion Resistant Pumps
Contents:
Installation Instructions:
Specifications:
page 2
page 3
Parts List/Torque Specs: page 4
Recommened
Spare Parts List
Exploded View/Kits:
Repair Instructions:
Pump mounting selection
Guide:
page 4
page 5
pages 6-7
page 7
Dimensions:
back page
Warranty Information
back page
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Specifications
Model P420A-3100/5100
Volume ................................................................................................... Up to 13.0 GPM (49 lm)
Discharge Pressure ................................................................................. Up to 2000 PSI (138 bar)
............................................................................................................... (at 11 GPM)
Inlet Pressure .......................................................................................... Up to 140 PSI (9.7 bar)
Stroke..................................................................................................... 24mm
RPM....................................................................................................... Up to 1460 RPM
Plunger Diameter.................................................................................... 25mm
Temperature of Pumped Fluids ............................................................... Up to 160 oF (71 oC)
Inlet Ports ............................................................................................... (2) 3/4" BSPP (P420A-5100)
Inlet Ports ............................................................................................... (2) 3/4" NPT (P420A-3100)
Discharge Ports ....................................................................................... (2) 3/4" BSPP (P420A-5100)
Discharge Ports ...................................................................................... (2) 3/4" NPT (P420A-3100)
Shaft Rotation............................................................................. Top of pulley towards fluid end
Crankshaft Diameter ............................................................................... 28mm
Key Width .............................................................................................. 8mm
Shaft Mounting....................................................................................... Either side1
Weight .................................................................................................... 36lbs. 11oz. (0.52 kg)
Crankcase Capacity ................................................................................ 30fl.oz. (0.89 liters)
Volumetric Efficiency @ 1460 ................................................................ 0.95
Mechanical Efficiency @ 1460 ............................................................... 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.
PULLEY INFORMATION
HORSEPOWER INFORMATION
Pulley selection and pump speed are based on a 1725 Horsepower ratings shown are the power require-
RPM motor and "B" section belts. When selecting ments for the pump. Gas engine power outputs must
desired GPM, allow for a ±5% tolerance on pumps be approximately twice the pump power require-
output due to variations in pulleys, belts and motors ments shown above.
among manufacturers.
1. Select GPM required, then select appropriate when selecting an electric motor as the power source.
motor and pump pulley from the same line. To compute specific pump horsepower requirements,
We recommend that a 1.1 service factor be specified
2. The desired pressure is achieved by selecting the use the following formula:
correct nozzle size that corresponds with the pump
GPM.
GPM X PSI
1450
=hp
P420A-3100/5100 PULLEY SELECTION & HORSEPOWER
REQUIREMENTS
PUMP
PULLEY
MOTOR
PULLEY
1000 1500 1700 2000
RPM GPM
PSI
4.8
5.5
6.2
PSI
7.2
8.3
PSI
8.2
9.4 11.0
PSI
9.6
785
900
7.0
8.0
7.75
7.75
7.75
7.75
7.75
7.75
4.50
5.00
5.75
6.00
6.75
7.75
1010 9.0
9.3 10.5 12.4
9.9
6.9 10.3 11.7 13.7
1120
1240
1460
11.0 7.6 11.4 12.9 15.2
13.0 8.9 13.4 15.2
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P420A-3100/5100 PUMP PARTS LIST
ITEM PART DESCRIPTION
QTY.
1
1
ITEM PART
DESCRIPTION
QTY.
3
1
08377
Crankcase
16G
17
07161-0100 Copper Washer
2
3
3A
4
5
5A
5B
6
08378 Oil Fill Plug with Gasket
06479 Crankcase cover
07186 Oil Sight Glass w/ Gasket
08380 O-Ring
12137 Oil Drain Plug
07182 Gasket for Oil Drain Plug
08092 Plug with Gasket
08093 Screw
07314
08366
08098
06613
07266
08059
12254
08099
12255
08376
06373
06614
06374
06615
06375
06376
08371
06377
08372
Crosshead Pin
3
3
3
3
3
3
3
3
3
6
3
1
1
6
6
6
6
6
6
6
6
6
6
6
6
8
1
1
1
1
1
1
1
1
4
12
1
1
1
2
8
1
1
1
1
19
20
21
21
22
23
23A
23B
24
25
26
26
27A
27A
27
28
29
Oil Seal
Seal Case
O-Ring (P420-3100)
O-Ring (P420-5100)
O-Ring
V-Sleeve
Spacer Ring
Weep Seal
Pressure Ring
Weep Return Ring
Manifold (P420-3100)
Manifold (P420-5100)
Valve Assembly (P420A-3100)
Valve Assembly (P420A-5100)
Valve Seat
Valve Plate
Valve Spring
Valve Spring Retainer
6A
7
08094 Spring Washer
08471
Bearing Cover, Open
08472 Bearing Cover, Closed
06245 Shim
8
8A
9
01016 O-Ring
10
11
12
12A
13
14
15
15A
16
16A
16B
16C
16D
16E
16F
08095 Screw with Washer
07459 Radial Shaft Seal
08473 Bearing
08474 Bearing
08475 Crankshaft
08091 Fitting Key
1
30
08390 Connecting Rod Assembly
07311 Screw with Washer
06611 Plunger Assy. Items 16A-16G
08096 Plunger Base
08398 Plunger Pipe
3
6
3
3
31
31
32
32
07212-0001 O-Ring, Viton (P420A-3100)
07212
06616
06379
O-Ring (P420A-5100)
Plug (P420A-3100)
Plug (P420A-5100)
3
33
07214-0001 O-Ring, Viton (P420A-3100)
07256 Centering Sleeve
08097 Tensioning Screwing
07023 O-Ring
3
3
3
33
34
36
07214
06612
13150
O-Ring (P420-5100)
Inner Hexagon Screw
Plug, G 3/4" (P420-5100)
07203 Backup Ring
3
37
13321-0100 Plug, G 1" (P420-5100)
P420A-3100/5100 PUMP TORQUE SPECIFICATIONS
Position
15A
16D
32
Item#
07311
08097
Description
Screw with Washer
Tensioning Screw
Plug (P420A-3100/P420A-5100) 125 ft.-lbs.
Inner Hexegon Screw 35 ft.-lbs.
Torque Amount
216 in.-lbs.
240 in.-lbs.
06616/06379
06612
34
Preventative Maintenance Check-List & Recommended Spare Parts List
Check
Daily
Weekly
50hrs
Every
500 hrs
Every
1500 hrs
Every
3000 hrs
Oil Level/Quality
Oil Leaks
Water Leaks
Belts, Pulley
Plumbing
X
X
X
X
X
Recommended Spare Parts
Oil Change
X
X
Seal Spare Parts (1 kit/pump)
(See page 5 for kit list)
Oil Seal Kit (1 kit/pump)
(See page 5 for kit lit)
X
X
Valve Spare Parts (1 kit/pump)
(See page 5 for kit list)
X
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EXPLODED VIEW - P420A-3100/5100 PUMPS
P420A-3100/5100 PUMP REPAIR KITS
Plunger Packing Kits
Oil Seal Kit
# 09306
# 09542 (P420-3100)
Item
21
Part # Description
Qty.
3
3
Item
19
Part # Description
08366 Oil Seal
Qty.
3
06613 O-Ring
08059 O-Ring
12254 V-Sleeve
22
23
3
Valve Assembly Kit (P420A-3100)
# 09522
Item Part #
27A 06615
23B
24
12255 Weep Seal
08376 Pressure Ring
3
6
Description
Valve Assembly, Complete
Qty.
6
33
07214-0001 O-Ring, Viton
6
Plunger Packing Kits
# 09140 (P420-5100)
Valve Assembly Kit (P420A-5100)
# 09478
Item Part #
27A 06375
33
Item
21
Part # Description
07266 O-Ring
08059 O-Ring
12254 V-Sleeve
Qty.
3
3
Description
Valve Assembly, Complete 6
O-Ring 6
Qty.
22
23
3
07214
23B
24
12255 Weep Seal
08376 Pressure Ring
3
6
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REPAIR INSTRUCTIONS - P420A-3100/5100 PUMPS
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.
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.
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.
2) Using needle nose pliers,
remove the inlet and dis-
charge valve assemblies
(27A). Note: It may become
neccesary to remove the
valve seat (27) from the
valve casing using
slidehammer.
a
6) Remove each seal case (20)
with o-rings and oil seals (21
and 22) from the crankcase
(1).
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. Re-
move the weep return rings
(25).
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.
19
22
20
21
24
23(B)
25
24
23 23A
Note: The orientation of oil seal in seal case is: seal lips
face crankcase.
8) Inspect all parts for wear and replace as needed.
7) Remove the pressure rings
(24), and v-sleeves (23) and
spacer ring (23A) from the
valve casing (26). Remove the
remaining v-sleeves (23B) and
pressure rings (24) from the
seal case (20).
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REASSEMBLY INSTRUCTIONS - P420A-3100/5100 PUMPS
9) Check surfaces of plunger
pipe (16B).
11) Place pressure rings and
weep seals (23B) over
plungers and into each seal
case (20).
10) Place each seal case (20)
with new o-rings (21 and
22) and new oil seals (19)
over plungers (16) with
weep hole down. Gener-
ously lubricate o-rings and
oil seals before reassembly.
14) 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 below).
4
1
6
8
2
3
7
5
12) Place weep return rings (25)
over the plunger (16) and
pressure ring over plunger
(24).
13) Generously lubricate
v-sleeves. Assemble spacer
rings (23A), and v-sleeves
(23) into valve casing (26).
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"xw=1.88"xh=3.00")
Contact Giant Industries for service school information. Phone: (419) 531-4600
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P420A-3100/5100 PUMP DIMENSIONS - 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.
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 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 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
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 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.
GIANT INDUSTRIES, INC., 900 N. Westwood Ave., P.O. Box 3187, Toledo, Ohio 43607
Ó Copyright 2002 Giant Industries, Inc.
10/02P420A-3100/5100.PM6
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