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
Exploded View/Kits:
Repair Instructions:
Dimensions:
page 5
pages 6-7
back page
back page
Warranty Information
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Specifications
Model P420A-3100/5100
Volume........................................................................................................ Up to 13.0 GPM
Discharge Pressure ..................................................................................... Up to 2000 PSI (at 11 GPM)
Inlet Pressure .............................................................................................. Up to 140 PSI
Stroke.......................................................................................................... 24mm
RPM............................................................................................................ Up to 1460 RPM
Plunger Diameter........................................................................................ 25mm
Temperature of Pumped Fluids .................................................................. Up to 160 oF
Inlet Ports.................................................................................................... (2) 1" BSPP
Discharge Ports........................................................................................... (2) 3/4" BSPP
Shaft Rotation ................................................................................ Top of pulley towards fluid end
Crankshaft Diameter................................................................................... 28mm
Key Width................................................................................................... 8mm
Shaft Mounting ........................................................................................... Either side1
Weight......................................................................................................... 36lbs. 11oz.
Crankcase Capacity .................................................................................... 30fl.oz.
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.
NOTES:
1 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
approximately twice the pump
power requirements shown above.
P420A-3100/5100
HORSEPOWERREQUIREMENTS
P420 HORSEPOWER
1000 1500 1700 2000
PSI PSI PSI PSI
RPM GPM
785 7.0 4.8 7.2 8.2 9.6
900 8.0 5.5 8.3 9.4 11.0
1010 9.0 6.2 9.3 10.5 12.4
1120 9.9 6.9 10.3 11.7 13.7
1240 11.0 7.6 11.4 12.9 15.2
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:
13.0 8.9 13.4 15.2
1460
HP = (GPM X PSI) / 1450
SPECIAL NOTE:
The theoretical gallons per revolution
(gal/rev) is 0.0089.
To find specific outputs at various RPM,
use the formula: GPM = 0.0089 x RPM
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P420A-3100/5100 PUMP PARTS LIST
ITEM PART DESCRIPTION
QTY.
ITEM PART
DESCRIPTION
QTY.
3
1
08377
Crankcase
1
16G
17
07161-0100 Copper Washer
2
08378 Oil Fill Plug with Gasket
06479 Crankcase cover
07186 Oil Sight Glass w/ Gasket
08380 O-Ring
1
07314
08366
08098
06613
07266
08059
12254
08099
12255
08376
06373
06614
06374
06615
06375
06376
08371
06377
08372
Crosshead Pin
3
3
1
19
Oil Seal
3
3A
4
1
20
Seal Case
3
1
21
O-Ring (P420-3100)
O-Ring (P420-5100)
O-Ring
3
5
12137 Oil Drain Plug
07182 Gasket for Oil Drain Plug
08092 Plug with Gasket
08093 Screw
1
21
3
5A
5B
6
1
22
3
1
23
V-Sleeve
3
4
23A
23B
24
Spacer Ring
3
6A
7
08094 Spring Washer
08471 Bearing Cover, Open
08472 Bearing Cover, Closed
06245 Shim
12
1
Weep Seal
3
Pressure Ring
6
8
1
25
Weep Return Ring
Manifold (P420-3100)
Manifold (P420-5100)
Valve Assembly (P420A-3100)
Valve Assembly (P420A-5100)
Valve Seat
3
8A
9
1
26
1
01016 O-Ring
2
26
1
10
11
12
12A
13
14
15
15A
16
16A
16B
16C
16D
16E
16F
08095
Screw with Washer
8
27A
27A
27
6
07459 Radial Shaft Seal
1
6
08473
08474
Bearing
Bearing
1
6
1
28
Valve Plate
6
08475 Crankshaft
08091 Fitting Key
08390 Connecting Rod Assembly
07311 Screw with Washer
06611 Plunger Assy. Items 16A-16G
08096 Plunger Base
1
29
Valve Spring
6
1
30
Valve Spring Retainer
6
3
31
07212-0001 O-Ring, Viton (P420A-3100)
6
6
31
07212
06616
06379
O-Ring (P420A-5100)
Plug (P420A-3100)
Plug (P420A-5100)
6
3
32
6
3
32
6
08398 Plunger Pipe
3
33
07214-0100 O-Ring, Viton (P420A-3100)
6
07256 Centering Sleeve
3
33
07214
06612
13150
O-Ring (P420-5100)
Inner Hexagon Screw
Plug, G 3/4" (P420-5100)
6
08097
Tensioning Screwing
3
34
8
07023 O-Ring
3
36
1
07203 Backup Ring
3
37
13321-0100 Plug, G 1" (P420-5100)
1
P420A-3100/5100 PUMP TORQUE SPECIFICATIONS
Position
15A
16D
32
Item#
07311
08097
Description
Torque Amount
216 in.-lbs.
240 in.-lbs.
125 ft.-lbs.
Screw with Washer
Tensioning Screw
Plug (P420, P422)
Inner Hexegon Screw
06616/06379
06612
34
35 ft.-lbs.
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EXPLODED VIEW - P420A-3100/5100 PUMPS
P420A-3100/5100 PUMP REPAIR KITS
Plunger Packing Kits
# 09542 (P420-3100)
Oil Seal Kit
# 09306
Item
21
22
Part # Description
Qty.
3
3
Item
19
Part # Description
08366 Oil Seal
Qty.
3
06613 O-Ring
08059 O-Ring
12254 V-Sleeve
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
07214-0100 O-Ring, Viton
6
Plunger Packing Kits
# 09140 (P420-5100)
Valve Assembly Kit (P420A-5100)
# 09478
Item
21
Part # Description
07266 O-Ring
08059 O-Ring
12254 V-Sleeve
Qty.
3
3
Item Part #
27A 06375
Description
Valve Assembly, Complete 6
O-Ring
Qty.
22
23
3
33
07214
6
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).
Contact Giant Industries or your local
distributor for maintenance of the gear
end of your pump. Phone: 419/531-4600
Contact Giant Industries for service school information. Phone: (419) 531-4600
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P420A-3100/5100 PUMP DIMENSIONS (INCHES)
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.
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
8/01P420A-3100/5100.PM6
Ó Copyright 2001 Giant Industries, Inc.
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