P400 Series - Triplex Ceramic

Plunger Pump
Operating Instructions/
18mm Versions Repair and Service Manual

For Models:
P435
P450
P451
P455B
P456B

Brass Version Shown

Contents:
Installation Instructions: page 2
Pump Specifications: pages 3
Exploded View: page 4
Parts List/Kits: page 5
Torque Specifications: page 5
Repair Instructions: pages 6-7
Dimensions: back page
Updated 06/22 Warranty Information back page
 INSTALLATION INSTRUCTIONS
Required NPSH refers to water (specific weight 1kg/
Safety Rules
dm3) at maximum permissible pump revolutions.
A safety valve is to be installed in accordance
with the guidelines for liquid spraying units so
Operation and Maintenance that the admissible operating pressure cannot be
exceeded by more than 10%. Pump operation
Check oil level prior to starting to ensure trouble-free without a safety vlave as well as any excess in
water supply. temperature or speed limits automatically voids
the warranty.
Important! If there is a danger of frost, the water
in the pump and in the pump fittings (particularly the When the pump is in operation, the drive shaft
unloader valve) must be emptied. The second dis- end and the coupling must be enclosed by a
charge port cal also be used and the pump run “dry” protective cover or a coupling bell.
for 1-2 minutes for this purpose.
Pressure in the discharge line and pump must
Oil amount: 30.4 ounces (0.9 liters). Only use ISO be at zero before any maintenance to the pump
VG 220 industrial gear oil (e.g. Aral Degol BG220) takes place. Shut off suction line. Disconnect
or automobile gear oil SAE 90 GL4 (Giant p/n fuses to ensure that the driving motor does not
01154). get switched on accidentally. Make sure that all
parts on the pressure side of the unit are vented
Initial oil change after 50 operating hours and then before starting the pump. In order to prevent air,
every 500 hours, after 1 year if used less. Caution or an air-water mixture being absorbed and to
when operating in damp places or with high temper- prevent cavitation occurring, the pump NPSHR
ature fluctuations. Oil must be changed immediately (=suction head) and water temperature must be
should condensate (frothy oil) occur in the gear box. respected.

NPSH values must be observed. Cavitation and/or compression of gases lead

to uncontrollable pressure kicks which can
Maximum input pressure 145 PSI (10 bar), maxi- ruin pump and unit parts and also be dan-
mum suction head -4.35 PSI (-0.3 bar). Make sure gerous to the operator or anyone standing
that suction pulsation is sufficiently dampened - wa- nearby.
ter column resonance must be avoided.
Giant Plunger Pumps are suitable for pumping
Important! If the pump is not used for a long period clean water and other non-agressive or non-
of time, it is possible the seals (23) could become abrasive media with a specific weight similar to
hard or brittle thus causing the pump to leak when water.
put into operation.
Before pumping other liquids - especially
If this is the case, we recommend these seals be inflammable, explosive and toxic media - the
replaced every 4 years. pump manufacturer must be consulted with
regard to the resistance of the pump mate-
rial. It is the responsibility of the equipment
manufacturer and/or operator to ensure that
all pertinent safety regulations are ahered to.

2
 PUMP SPECIFICATIONS - P400 - 18MM PUMPS
U.S. Measurements
Max. Flow Max. Max. Power Max. Plunger Stroke Weight
Pressure Speed Required Temp Diameter
Model GPM PSI RPM HP F in in lbs
P450 5.5 5100 1450 19.8 160 0.71 0.79 38.3
P455B 5.5 4350/5100+ 1450 16.5/19.2+ 160 0.71 0.79 38.3
P451 5.8 5100 1725 20.4 160 0.71 0.72 38.3
P456B 5.8 4350/5100+ 1725 17.4/20.3+ 160 0.71 0.72 38.3
P435 6.6 3625 1450 16.5 160 0.71 0.94 38.3

Metric Measurements
Max. Flow Max. Max. Power Max. Plunger Stroke Weight
Pressure Speed Required Temp Diameter
Model L/min Bar RPM kW C mm mm kg
P450 20.8 350 1450 14.8 70 18 20 17.4
P455B 20.8 300/350+ 1450 12.3/14.3+ 70 18 20 17.4
P451 22.0 350 1725 15.2 70 18 18.2 17.4
P456B 22.0 300/350+ 1725 13.0/15.1+ 70 18 18.2 17.4
P435 25.0 250 1450 12.3 70 18 24 17.4
+Continuous/Intermittent Duty

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.

Horsepower Ratings:
We recommend a 1.15 service factor be specified 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 flows 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

Common Specifications: Materials Used for P400 Pumps:

Inlet Pressure.......................145 PSI (10 Bar) Manifold
Crankshaft Diameter............1.1” (28mm) (P450/P451).... Aluminum Bronze
Keyway Width.......................8mm (others)............ Forged Brass
Crankcase Oil Capacity........30.4 fl. oz. (0.9 L) Plungers.......... Solid Ceramic Oxide
Inlet Ports.............................(2) 3/4” or (2) 1/2" BSP* Valves.............. 316 Stainless Steel
Discharge Ports....................(2) 1/2” BSP Seals............... Nitrile with Fabric Reinforcing
Shaft Rotation.....Top of Pulley Toward Fluid End Gear End......... Aluminum

*1/2" BSP for P450/P451/P456 and

3/4" BSP for P435 and P455
3
EXPLODED VIEW - P435/P450/P451/P455B/P456

4
 P435/P450/P451/P455B/P456 SPARE PARTS LIST

ITEM PART DESCRIPTION QTY. ITEM PART DESCRIPTION QTY.

1 08377 Crankcase 1 16F 07203 Backup Ring 3
2 08378 Oil Fill Plug with Gasket 1 16G 07258 Copper Washer 3
3 06479 Crankcase cover 1 16H 06431 Oil Scraper 3
3A 07186 Oil Sight Glass w/ Gasket 1 17 06790 Crosshead Pin 3
4 08380 O-Ring 1 19 05444 Oil Seal 3
5 07109 Oil Drain Plug 1 20 05534 Seal Case 3
5A 06015 O-Ring for Oil Drain Plug 1 21 07266 O-Ring 3
5B 08092 Plug with Gasket 1 23 08477 V-Sleeve, 18mm 6
6 01010 Screw 4 24 07929 Pressure Ring 3
6A 01011-0400 Spring Washer 4 25 03476 Weep Return Ring 3
7 04739 Bearing Cover Open 1 26 05574 Manifold (P435/P455/P456) 1
8 05291 Bearing Cover Closed 1 26 08470 Manifold (P450/P451) 1
8A 05292 Shim 1-3 27A 05543 Valve Assembly (Items 27-31) 6
8B 05293 Shim (May not be present) 1 27 05541 Valve Seat 6
8C 05964 Shim 1-2 28 05542 Valve Plate 6
9 01016 O-Ring 2 29 07906 Valve Spring 6
10 07114 Screw with Washer 8 30 07907 Valve Spring Retainer 6
11 07459 Radial Shaft Seal 1 31 07770 O-Ring 6
12 05350 Taper Roller Bearing 2 32 05544 Plug (P435/P455/P456) 6
13 04741 Crankshaft (P435) 1 32 08406 Plug (P450/P451) 6
13 04740 Crankshaft (P450/P455B) 1 33 05545 O-Ring (P435/P455/P456) 6
13 03173 Crankshaft (P451/P456) 1 33 07489 O-Ring (P450/P451) 6
13A 04742 Spacer Ring 1 34 08484 Cap Screw (P435/P455/P456) 8
14 08091 Fitting Key 1 34 08396 Cap Screw (P450/P451) 8
15 08390 Connecting Rod Assembly 3 36 13434 Plug, 1/2" BSP (P435/P455/P456) 1
16 05484 Plunger Assy.(Items 16A-16H) 3 36 13434 Plug, 1/2" BSP (P450/P451) 2
16A 05352 Plunger Base 3 36A 06272 Copper Washer (P435/P455/P456) 1
16B 08397 Plunger Pipe 3 36A 06272 Copper Washer (P450/P451) 2
16D 08399 Tension Screw 3 37 07703 Plug, 3/4" BSP (P435/P455/P456) 1
16E 07023 O-Ring 3

P435/P450/P451/P455B/P456 REPAIR KITS

Plunger Packing Kit - # 09141 Valve Assembly Kits
Item Part# Description Qty P435/P455/P456 - # 09644
21 07266 O-Ring 3 Item Part # Description Qty
23 08477 V-Sleeve 6 27A 05543 Valve Assembly, Complete 6
24 07929 Pressure Ring 3 33 05545 O-Ring 6

Oil Seal Kit - #09641 P450/P451 - # 09770

Item Part # Description Qty Item Part # Description Qty
19 05444 Oil Seal 3 27A 05543 Valve Assembly, Complete 6
33 07489 O-Ring 6

TORQUE & LUBRICATION SPECIFICATIONS - P435/P450/P451/P455B/P456

Position Item # Description Lubrication Information Torque Amount
3A 07186 Oil Sight Glass Loctite 5910 106 in.-lbs. (12 Nm)
5 07109 Oil Drain Plug 59 ft.-lbs. (80 Nm)
5B 08092 Plug with Gasket 59 ft.-lbs. (80 Nm)
6 01010 Screw 110 in.-lbs. (12.5 Nm)
10 07114 Screw with Washer 132 in.-lbs. (15 Nm)
15 08390 Screw with Washer 97 in.-lbs. (11 Nm)
16D 08399 Tension Screw Loctite 243 247 in.-lbs. (28 Nm)
32 05544/08406 Plug Loctite 243 125 ft.-lbs. (170 Nm)
34 08396/08484 Cap Screw Lightly Oil 30 ft.-lbs. (40 Nm)
5
 REPAIR INSTRUCTIONS - P435/P450/P451/P455B/P456
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 2) Using needle nose pliers, 3) By inserting a small screw-
the three discharge valve remove the inlet and discharge driver between the valve
plugs and three inlet valve valve assemblies (27A). seat (27) and the valve
plugs (32). Inspect the o-ring Note:It may become neccesary spring retainer (30), the
(33) for wear and replace if to remove the valve seat (27) valve assembly can be
damaged. from the valve casing using a separated.
slidehammer.

4) Remove the o-ring (31). 5) Use a 8mm allen wrench to 6) Remove seal adaptors (20) and
Inspect all parts for wear and remove the 8 socket head weep return rings (25) from the
replace as necessary. Apply cap screws (34). Carefully valve casing.
one drop of loctite 243 to the slide the valve casing (26)
valve plugs (32) and tighten out over the plungers.
to 125 ft. lbs. (170 Nm).
IMPORTANT! The grooved
seal (23) on the high-pressure
side is to be fitted carefully into
the valve casing (26) using a
screwdriver. Under no circum-
stances must the seal surface
in the valve casing or the seal
lip be damaged.

7) Remove the pressure rings 8) Remove the weep grooved

(24) and v-sleeves (23) seal (23) out of the seal
from the valve casing (26). adaptor (20). Check O-rings
(21).
9) Check surfaces of plunger (16). Damaged surfaces cause accelerated seal wear.
Deposits of all kinds must be removed from the plungers.

IMPORTANT! 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.

6
 REPAIR INSTRUCTIONS - P435/P450/P451/P455B/P456
10) If the plunger pipe (16B) is worn,
IMPORTANT! Care must be
remove tension screw (16D) and
taken that glue does not get
remove along with plunger pipe
between the plunger pipe (16B)
(16B). Check and clean plunger
and centring sleeve (16C). The
surface (16A), check oil scraper
plunger pipe should not be
(16H). Cover thread of tension
strained by eccentric tightening
screw (16D) with a thin film of
of the tension screw or through
Loctite and tighten carefully to 247
damage to front surface of
in.-lbs. (28 Nm).
plunger, otherwise it is liable to
fracture.

11) After installation of high pressure seals (23), place seal adaptor (20)
with weep seals & pressure ring installed, weep return ring (25) and high
pressure weep return ring (24) over plungers. Slide valve casing over 6 4 2 7
plungers and seat firmly. Replace the 8 socket head cap screws (34)
and tighten to 30 ft.-lbs. (40 Nm) in a crossing pattern (as shown to the
right). 8 1 3 5

Gear End
If oil leaks where the plunger (16) extends from the crankcase (1), the oil seals (19) and plungers (16) must be
examined and replaced if necessary. Remove oil plug (5) and drain oil; remove crankcase cover (3). Remove
valve casing (26), and seal case (20). Then remove plunger pipes (16B) and oil scrapers (16H) as described
above.

IMPORTANT! Before removing connecting rods be aware of their position on the crankshaft so as to return them
to the same location and orientation when re-assembling.

Remove screws from connecting rods (15), separate the back connecting rod half from the crankshaft and the
front connecting rod half. The connecting rod halves must be kept as pairs - do not mix them up. Push connecting
rod shaft as far as possible into the crosshead guide. Remove screws (10) and pry bearing covers (7,8) off gently
with a screwdriver.

Carefully remove crankshaft (13) by threading it through the connecting rods (15), making sure not to bend the
connecting rods. Remove and disassemble connecting rods and plungers (16) paying close attention not to dam-
age the plungers. Pry out oil seal (19) using a screwdriver. Examine plunger surfaces (16A) and replace if neces-
sary.

To re-assemble, first press the oil seal (19) into the crankcase. Then insert connecting rods with plungers remem-
bering their original location. Thread in the crankshaft (13). Replace bearing cover (7) and o-ring (9) together
with the radial shaft seal (11) and roller bearing (12) and fix in place with screws (10). Replace roller bearing (12),
bearing cover (8) and o-ring (9). Adjust the clearance by fitting shims (8A) under the bearing cover as required
to ensure that the crankshaft (13) turns easily without play being felt. Finally, mount connecting rod halves on
crankshaft matching them with other half and tighten screws (15) to 97 in-lb (11 Nm). Replace crankcase cover
(3) and o-ring (4). When remounting the valve casing (26), tighten hexagon socket screws (34) to 30 ft.-lb (40
Nm).

To Move Crankshaft to Opposite Side

Remove the valve casing (26) and seal case (20). Then rotate the crankcase 180°. Interchange the oil plug ((5B)
with oil dipstick (2). Rotate the crankcase cover (3) 180°. Remount the valve casing together with the seal casing
and the seal adapters (20). Make sure that the seal adapters are rotated in order that the bores face down-
wards.

Contact Giant Industries for service school information.

Phone: (419) 531-4600
7
P435/P450/P451/P455B/P456 Dimensions - in (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. Five (5) years from the date of shipment for all pumps used in portable pressure
washers with NON-SALINE, clean water applications.
2. Two (2) years from the date of shipment for Giant pumps used in car wash
applications.
3. One (1) year from the date of shipment for all other Giant industrial and consumer
pumps.
4. Six (6) months from the date of shipment for all rebuilt pumps
5. 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 WARRANTIES
OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE AND ALL SUCH WARRANTIES
ARE HEREBY DISCLAIMED AND EXCLUDED BY THE MANUFACTURER.

WARNING: This product might contain a chemical known to the State of California to cause cancer,
and birth defects or other reproductive harm.
For more information go to [Link]

GIANT INDUSTRIES, INC.

900 N. Westwood Ave., Toledo, Ohio 43607
PHONE (419) 531-4600 FAX (419) 531-6836
[Link]
© Copyright 2022 Giant Industries, Inc.
06/22 P435_P450_P451_P455_P456.indd