Triplex Ceramic
Plunger Pump
Operating Instructions/
Repair and Service
Manual
Models
P46W, P46W-HK & P46HT
Contents:
Installation Instructions: page 2
Pump Specifications:
Kits/Torque Specs:
Exploded View:
Parts List:
page 3-4
page 5
page 6
page 7
Trouble Shooting:
Repair Instructions:
Dimensions:
page 8
page 9-11
back page
back page
Warranty Information:
Updated 5/01
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Specifications
Model P46W/P46W-HK
Volume........................................................................................................ Up to 3.9 GPM
Discharge Pressure ..................................................................................... 2200 PSI
Inlet Pressure .............................................................................................. -4.35 - 140 psi
Maximum Crankshaft Rotation Speed ....................................................... Up to 1420 RPM
Stroke.......................................................................................................... 14.1mm
Crankcase Oil Capacity .............................................................................. 8 fl. oz.
Temperature of Pumped Fluids .................................................................. Up to 220oF
Plunger Diameter........................................................................................ 18mm
Inlet Ports.................................................................................................... (2) 1/2" BSP
Discharge Ports........................................................................................... (2) 3/8" BSP
Pulley Mounting ......................................................................................... Either Side
Shaft Rotation ................................................................................ Top of pulley towards Head
Weight......................................................................................................... 16 lbs.
Crankshaft Diameter................................................................................... 18mm
Volumetric Efficiency @ 1420 ................................................................... 0.96
Mechanical Efficiency @ 1420 .................................................................. 0.80
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,
2. The desired pressure is achieved by selecting the use the following formula:
We recommend that a 1.1 service factor be specified
correct nozzle size that corresponds with the pump
(GPH X PSI) / 1460 = HP
GPM.
P46W & P46W-HK PULLEY SELECTION &
HORSEPOWER REQUIREMENTS
PUMP MOTOR
PULLEY PULLEY
RPM GPM 1000 PSI 1500 PSI 1700 PSI 2200 PSI
7.75"
7.75"
7.75"
7.75"
7.75"
3.55"
4.25"
5.25"
5.95" 1305 3.6
6.45" 1420 3.9
745 2.0
910 2.5
1140 3.1
1.4
1.7
2.1
2.5
2.7
2.1
2.6
3.2
3.7
4.0
2.3
2.9
3.6
4.2
4.5
3.0
3.8
4.7
5.4
5.9
3
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Specifications
Model P46HT
Volume........................................................................................................ Up to 123 GPH (2.1 PGM)
Discharge Pressure ..................................................................................... 900 PSI
Inlet Pressure .............................................................................................. See NPSHR curve below
Maximum Crankshaft Rotation Speed ....................................................... 900 RPM
Plunger Diameter........................................................................................ 18mm
Crankcase Capacity .................................................................................... 8 fl. oz.
Temperature ................................................................................................ Up to 220oF
Inlet Ports.................................................................................................... (2) 1/2” BSP
Discharge Ports ........................................................................................... (2) 3/8” BSP
Pulley Mounting ......................................................................................... Either Side
Shaft Rotation ............................................................................................. Top of pulley towards head
Weight......................................................................................................... 16 lbs.
Crankshaft .................................................................................................. 18 mm
23
20
16
13
10
6.6
3.3
0
200
400
600
800
1000
1200
1400
1600 1700
RPM
NPSHR Chart
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 RPM
motor and "B" section belts. When selecting desired GPM,
allow for a ±5% tolerance on pumps output due to variations
in pulleys, belts and motors among manufacturers.
1. Select GPM required, then select appropriate motor
and pump pulley from the same line.
Horsepower ratings shown are the power requirements for
the pump. Gas engine power outputs must be approxi-
mately twice the pump power requirements shown above.
We recommend that a 1.1 service factor be specified when
selecting an electric motor as the power source. To compute
specific pump horsepower requirements, use the following
formula:
2. The desired pressure is achieved by selecting the
correct nozzle size that corresponds with the pump GPM.
(GPH X PSI) / 1440 = HP
P46HT PULLEY SELECTION & HORSEPOWER
REQUIREMENTS
PUMP MOTOR
PULLEY PULLEY
RPM GPM GPM 200 PSI 400 PSI 600 PSI 900 PSI
385 0.9 54.0
676 1.6 96.0
900 2.1 123
0.1
0.2
0.3
0.2
0.4
0.6
0.4
0.7
0.9
0.6
1.0
1.3
7.75"
7.75"
7.75"
2.0"
3.25"
4.25"
4
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P46W, P46W-HK & P46HT REPAIR KITS
Ceramic Plunger Assembly Kit #09082
Plunger Packing Kit, P46W #09038
Item
24A
24B
24C
25
Part #
07021
08456
07676
Description
Qty.
3
3
3
3
Item
31
40
Part # Description
07241 V-Sleeve
07234 O-Ring
Qty.
3
3
Ceramic Plunger
Tension Screw
Copper Ring
06648/13333* Flinger
* p/n 13333 is needed for older P46W pumps with brass
retainers (p/n 08064).
Complete Plunger Packing Kit, P46W #09081
Item
31
40
Part # Description
07241 V-Sleeve
07234 O-Ring
Qty.
3
3
Valve Assembly Kit P46W & P46W-HK #09039
50
51
07239 Rear V-Sleeve
07240 Support Ring,
Rear V-Sleeve
3
Item
34
35
36
37
38
40
42
44
Part #
07325
Description
Spring Retainer
Qty.
3
3
3
3
3
3
3
3
06017-0100 Valve Spring
06016
06014
06015
07234
12004
07035
Valve Plate
Valve Seat
O-Ring, Valve Seat
O-Ring,Adapter
O-Ring, Manifold Plug
Plunger Packing Kit, P46W-HK, P46HT #09514
Item
31A
40
50
51
Part #
11511
07234
11512
07240
Description
Sleeve
O-Ring,Adapter
High Temp. Rear Seal
Support Ring
Qty.
3
3
6
3
O-Ring, Discharge Plug 3
ValveAssembly Kit, P46HT #09497
Item
34
35
36
37
38
40
42
44
Part #
Description
Qty.
3
3
3
3
3
3
3
06018-0100 Valve Cage
06017-0100 Valve Spring
06016
06014
06015
07234
12004
07035
Valve Plate
Valve Seat
O-Ring
O-Ring,Adaptor
O-Ring, Manifold Plug
O-Ring, Discharge Plug 3
P46W, P46W-HK & P46HT TORQUE SPECIFICATIONS
Position
Item#
08456
07235
07034
08040
Description
Torque Amount
105 in-lbs.
24B
41
43
Tension Screw, Plunger
Plug, Manifold (Inlet)
Plug, Manifold (Outlet)
Hex Nut, Manifold Stud
52 ft.-lbs.
52 ft.-lbs
35 ft.-lbs
46
5
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Exploded View - P46W, P46W-HK, P46HT
6
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P46W, P46W-HK & P46HT PARTS LIST
ITEM PART
DESCRIPTION
Support Ring
QTY.
ITEM PART
DESCRIPTION
Crankcase
QTY.
32
33
34
07231
07232
07325
3
3
1
07222
07181
07182
08004
08005
08008
01009
07188
07223
1
1
1
1
1
1
1
4
Pressure Spring
Retainer, Spring
(P46W, & P46HT)
2
Vent/Filler Plug with Seal
Gasket, Oil Filler Cap
Cover, Crankcase
O-Ring
2A
3
6
6
6
6
6
6
3
3
3
34 06018-0100 Retainer, Spring (P46HT)
35 06017-0100 Valve Spring
4
5
Oil Dipstick
36
37
38
39
40
41
42
43
06016
06014
06015
07233
07234
07235
12004
07034
Valve Plate
6
O-Ring
Valve Seat
9
Cylinder Screw with Slot
Spring Washer
O-Ring
10
Suction Valve Adaptor
O-Ring, Adapter
Plug Manifold (Inlet)
(Excluding P46HT)
4
10 07223-0100 Spring Washer (P46HT only) 4
11
08012
06709
07224
08015
08020
07225
07226
07227
01024
08024
07201
01031
07021
08456
07676
06648
07206
11510
07207
07033
07230
07241
11511
Oil Drain Plug with Seal
Gasket, Oil Drain Plug
Bearing Cover
Radial Shaft Seal
Ball Bearing
1
1
2
2
2
6
1
1
1
3
3
3
3
3
3
3
3
3
2
1
3
3
O-Ring, Manifold Plug (Inlet)3
Plug & O-Ring
11A
12
(P46W & P46W-HK)
Plug & O-Ring (P46HT)
O-Ring for 43
3
3
3
2
2
2
1
14
43
44
45
46
47
48
49
07792
07035
07215
08040
08041
07237
07238
15
16
Screw and Washer
Shaft Protector
Crankshaft
Stud, Manifold
17
Hex Nut, Manifold Stud
Spring Washer, Stud
Housing, Rear V-Sleeve
O-Ring, Rear
18
19
Key
20
Connecting Rod
Crosshead Assy.
Crosshead Pin
Plunger Pipe
22
V-Sleeve Housing
1
23
50
50
07239
11512
Rear V-Sleeve (P46W only) 3
High Temperature Seal
24A
24B
24C
25*
26
Tension Screw
Copper Ring
(P46W-HK & P46HT)
6
51
07240
07109
07110
13338
08486
Support Ring, Rear V-Sleeve 3
Flinger
52
Plug, 1/2" BSP
Gasket
1
1
1
Radial Shaft Seal
Spacer Sleeve
52A
53
26A
28
Plug, 3/8" BSP
Copper Crush Washer
(P46W & P46W-HK)
Shim, Manifold Stud
Manifold
53A
29
1
30
Pressure Ring
31
V-Sleeve (P46W only)
V-Sleeve, High Temp.
(P46W-HK, P46HT)
31A
3
* This will not fit into older P46W pumps with brass retainers (#08064). It can only be used with part number 11510 (#26A).
You can substitute p/n 13333 for 06648 only if the brass retainer (#08064) is used.
7
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PUMP SYSTEM MALFUNCTION
MALFUNCTION
CAUSE
REMEDY
The Pressure and/
or the Delivery
Drops
Worn packing seals
Broken valve spring
Belt slippage
Worn or Damaged nozzle
Fouled discharge valve
Fouled inlet strainer
Worn or Damaged hose
Replace packing seals
Replace spring
Tighten or Replace belt
Replace nozzle
Clean valve assembly
Clean strainer
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
Noisy Operation
High humidity
Worn seals
Reduce oil change interval
Replace seals
Worn bearings
Cavitation
Replace bearings, Refill crankcase
oil with recommended lubricant
Check inlet lines for restrictions
and/or proper sizing
Rough/Pulsating
Operation with
Pressure Drop
Worn packing
Inlet restriction
Replace packing
Check system for stoppage, air
leaks, correctly sized inlet
plumbing to pump
Accumulator pressure
Unloader
Cavitation
Recharge/Replace accumulator
Check for proper operation
Check inlet lines for restrictions
and/or proper size
Pump Pressure as
Drop at gun
Restricted discharge plumbing
Re-size discharge plumbing to
flow rate of pump
Rated, Pressure
Excessive
Leakage
Worn plungers
Replace plungers
Worn packing/seals
Excessive vacuum
Cracked plungers
Inlet pressure too high
Adjust or Replace packing seals
Reduce suction vacuum
Replace plungers
Reduce inlet pressure
High Crankcase
Temperature
Wrong Grade of oil
Improper amount of oil in crankcase
Giant oil is recommended
Adjust oil level to proper amount
8
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REPAIR INSTRUCTIONS - P46W, P46W-HK, P46HT
1. With a 22mm socket, remove
the three discharge (43) and
three inlet (41) manifold plugs.
Check o-rings (42 & 44) for
wear and replace as necessary.
2. Remove the discharge spring
retainer (34), valve spring (35),
and valve plate (36).
3. Use a small slide hammer to
remove valve seats (37) from
manifold (29). Inspect valve
plates (36) and valve seats (37)
for wear. If excessive pitting is
seen, replace the worn parts.
Check valve seat o-ring (38) for
wear and replace as necessary.
4. Drain the oil from the pump.
Turn the pump over to remove
the two manifold stud nuts (46)
with a 17mm wrench.
5. Tap the back of the manifold
(29) with a rubber mallet to
dislodge, and slide off the
pump.
6. From the front inlet valve ports,
remove the inlet valve assembly
(34-40).
34
35
36
40
37
39
7. Inspect and clean the valve assembly parts. If pitted or worn, replace inlet
valve seats (37), valve plates (36), spring (35) and spring retainers (34).
Reinsert items 34-38 into valve adapter (39).
NOTE: Contact Giant Industries for Service School Information. Phone: (419)-531-4600
9
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REPAIR INSTRUCTIONS - P46W, P46W-HK, & P46HT
49
30
31/50
31A
32
38
33
(P46W-HK & P46HT only)
8. The pressure rings (item 30) can now be removed by pulling straight out.
Inspect and clean manifold (29) and pressure ring. Replace if necessary.
From the front of the pump reinstall pressure rings into manifold (29) with
grooved side towards front of manifold. Install new v-sleeves (31 or 50),
with grooved sides towards front of pump. For P46W-HK & P46HT pumps,
install high temperature seal (31A) with grooved sides towards front of
pump. Replace the support rings (32) and pressure springs (33) into mani-
fold (29). Install valve assembly (34-40) into manifold (29). Reinstall
manifold plugs (43) and torque plugs to 52 ft.-lbs.
50
51
9. The rear V-sleeve housing (48)
may be removed by prying
evenly outward with a flat
screwdriver. After slipping
housing over plunger, inspect
seals (50) and O-ring (49) and
replace as necessary.
24C
10.Inspect ceramic plunger (24A)
tips for wear. If necessary,
replacement of the ceramic
plungers may be accomplished
by removing the plunger bolt
assemblies (24B and 24C) with
a 13mm wrench. Ceramic
plungers should now slide off
the stainless steel plunger base
(22). Excessive resistance to
plunger removal may be
11.Replace copper ring (24C) onto
plunger bolt (24B). Slide
plunger bolt assembly into
ceramic plunger (24A). Apply
a light film of loc-tite to
13.Before replacing pump manifold
(29), first rotate crankshaft (18)
until two outside plungers (24A)
extend evenly forward. Next
lubricate v-sleeves (50) in the rear
v-sleeve housing (48) and slide
housing over plungers. Lubricate
ceramic plungers with a light film
of oil. Carefully and evenly slide
manifold over plungers and press
manifold firmly against crankcase
(1). Replace manifold stud bolts
(45), washers (47) and nut (46)
and tighten to 35 ft.-lbs.
plunger bolt threads and place
plunger assembly onto stainless
steel plunger base (22) and
tighten to 105 in.-lbs.
12.To replace plunger oil seals
(26), proceed to “Gear End
Disassembly” section below.
Otherwise, continue as de-
scribed below.
overcome by heating the
stainless steel plunger base.
This will melt any excess loc-
tite beneath the ceramic plunger
allowing easy removal.
NOTE: Contact Giant Industries for Service School Information. Phone: (419)-531-4600
10
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REPAIR INSTRUCTIONS - P46W, P46W-HK, & P46HT
Gear End Disassembly
14.Remove the crankcase cover bolts (9). Inspect the crancase cover O-ring (4) for wear. Replace if necessary.
15.Inspect the dip stick (5) vent hole for signs of clogging. Clean if necessary.
16.To remove the crankshaft (18), first remove the bearing cover plates (12) Remove the key (19).
17.Hold the pump rear assembly with a wooden fixture, or other suitable device, in order to secure it while removing the
crankshaft (18). Using a plastic mallet, tap the crankshaft (18) from one side while turning it from the other side. The
turning insures that during this sequence the crankshaft does not become wedged agaisnt the connecting rods (20). The
far side bearing (15) will remain in the crancase (1). When free, the crankshaft (18) can be removed by hand.
18.The crankshaft bearing (15) remains on the crankshaft (18) as it is removed. The near side crankshaft seal (14) will be
removed by this procedure.
19.If necessary, use a bearing puller to remove crankshaft bearing (15).
20.Remove the connecting rod (20) and plunger rod/crosshead assembly (22) from the rear of the pump by pulling
straight out of the crosshead guides.
21.To remove the crankcase oil seal (26), tap oil seal out from the rear of the crankcase using a dowel and rubber mallet.
The area onto which the oil seal rests should be clean and dry. Put a small drop of loc-tite on the oil seals and place
into crankcase with clips facing the rear of the pump.
22.To remove the crosshead pin (23) from the crosshead (22), the assembly should be positioned on a wooden fixture to
avoid damage to crosshead. Drive out pin (23) on opposite side of mark on the crosshead. On those pumps without
mark on crosshead, drive out pin by tapping on tappered side of pin.
23.To remove the bearing remaining in the crankcase, insert small end of Giant Bearing tool and tap with a rubber mallet
untill bearing and seal are completely removed. The bearing can only be removed from the inside by inserting the
Giant Bearing Tool through the opposite side of the crankcase (1) and should be inspected for possible damage.
Gear End Reassembly
24.To reassemble, place the far bearing in the crankcase bearing housing and with the Giant Bearing tool as a driver, tap
into the crankcase (1) using a rubber mallet.
25.Insert the far side crankshaft oil seal (14) with the Giant Bearing Tool making sure it is firmly seated and well oiled.
Always make sure that the crankshaft seal (14) lip does not show signs of wear. Replace the bearing cover (12) and
tighten securely.
26.Replace the connecting rod (20) and plunger rod/crosshead assembly (22) by press-fitting the crosshead pin (23).
Make sure to insert the beveled edge of the crosshead pin into crosshead. If the crosshead has a mark, install pin
frommarked side. The crosshead pin (23) should not extend beyond either side of the crosshead in order to prevent
damage to the crosshead bore of the crankcase.
27.Place each crosshead/plunger assembly (22) into the pump making sure that all of the parts are well oiled before
insertion into the crankcase.
28.Replace near side bearing on crankshaft (18) and mallet to tap into place.
29.Take the crankshaft (18) end with the bearing and insert the other end through the bearing housing carefully threading
the lobes of the crankshaft through the well lubricated connecting rods (20). Turning the crankshaft while tapping it
through the connecting rods will help prevent binding and possiable damage to the connecting rods. Continue tapping
the crankshaft through the connecting rods (20) until it is firmly seated into far side bearing.
30. Insert the near side crankshaft oil seal (14), making sure it is firmly seated and well oiled. Replace the bearing cover
(12) and tighten securely.
31.See instructions (13 above) for re-installing fluid end onto gear end.
32.Clean the back edge of crankcase and replace the crankcase cover. Be careful not to pinch the crankcase cover o-ring.
33.Fill the P46W crankcase with 8 oz. of Giant oil. and check the oil level with the dipstick. Proper level is center of two
lines Reinstall the pump into your system.
11
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P46W, P46W-HK & P46HT DIMENSIONS
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 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.
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
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-
RANTIESORMERCHANTABILITYORFITNESSFORAPARTICULARPURPOSEANDALLSUCH
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 1998 Giant Industries, Inc.
5/01 P46W, P46W-HK, & P46HT & P46HT.PM6
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