GIANT PUMPS P55W Setup guide

8
1. With a 22mm socket, remove
the three discharge (43)
and three inlet (41) manifold
plugs. Check o-rings (42 and
44) for wear and replace as
necessary.
Repair Instructions
P55W/P56W/P56W-HK/P56W-0011/P56W-0021/P56W-0121
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.
3. Using a small slide hammer
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 re-
place as necessary. Tighten
manifold plugs (43) to 52
ft.-lbs. (70 Nm).
2. Remove the discharge
spring retainer (34), valve
spring (35), and valve plate
(36).
8. Inspect and clean the manifold (29) and pressure ring
(32). Reinstall the pressure ring (30) with the groved side
pointed towards the front. Insert v-sleeves (31/31A), sup-
port ring (32), and pressure spring (33) into the manifold.
30 32 33
4. Drain the oil from the pump.
Turn the pump over to
remove the four manifold
stud nuts (46) with a 17mm
wrench.
7. Turn the manifold (29) over.
Using a 15mm socket, tap
out the v-sleeves (31/31A-
for P56W-HK), support rings
(32), and pressure rings (30)
through back of manifold.
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) and pres-
sure springs (33).
31 31A
(P56W-HK only)

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14. 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 plung-
ers and press manifold
firmly against crankcase (1).
Replace manifold stud bolts
(45), washers (47) and nut
(46) and tighten to 35 ft.-lbs.
(47.5 Nm).
11.Inspect ceramic plunger
(24A) tips for wear. If neces-
sary, replacement of the
ceramic plungers may be
accomplished by removing
the plunger bolt assemblies
(24B and 24C) with a 13mm
wrench. Ceramic plung-
ers should now slide off the
stainless steel plunger base
(22). Excessive resistance
to plunger removal may be
overcome by heating the
stainless steel plunger base.
This will melt any excess
loc-tite beneath the ceramic
plunger allowing easy re-
moval.
12. Replace copper ring (24C)
onto plunger bolt (24B). Slide
plunger bolt assembly into ce-
ramic plunger (24A). Apply a
light film of loc-tite to plunger
bolt threads and place plunger
assembly onto stainless steel
plunger base (22) and tighten
tension screw (24B) to 199
in.-lbs. (22.5 Nm).
13. To replace plunger oil seals
(26), proceed to “Gear End
Disassembly” section below.
Otherwise, continue as de-
scribed below.
24C
9. If pitted or worn, replace inlet valve seats (36),
valve plates (37), springs (35) and spring
retainers (34). Re-insert items 34-38 into valve
adapter (39). Install valve assembly (34-40) into
manifold (29). Reinstall manifold plugs (41) and
torque plugs to 52 ft.-lbs. (70 Nm).
36 37 35 34
10. The rear v-sleeve
housing (48) may be
removed by prying
evenly outward with a
flat screwdriver. After
slipping housing over
ceramic plunger (24A),
inspect seals (50) and
o-ring (49) and replace
as necessary. If the
crankcase is to be dis-
assembled, the housing
should not be replaced
until later.
48
49
50
Repair Instructions
P55W/P56W/P56W-HK/P56W-0011/P56W-0021/P56W-0121

10
Gear End Disassembly
NOTE: The manifold (29) weep seal housing (48) and spacer sleeve (26A) must be removed. See above for
directions.
15. Remove the crankcase cover screws (9). Inspect the crankcase cover o-ring (4) for wear. Replace if neces-
sary.
16. Inspect the dipstick (5) vent hole for signs of clogging. Clean if necessary.
17. To remove the crankshaft (18), first remove the bearing cover plates (12). Remove the key (19).
18. With a 5 mm allen wrench remove the connecting rod screws (21) and rear portion of connecting rod assem-
blies (20). Push the connecting rod (20) and plunger rod (22) down as far as possible into the crankcase hous-
ing.
19. Hold the pump rear assembly with a wooden fixture, or other suitable device, in order to secure it while remov-
ing the crankshaft (18). Using a plastic mallet, tap the crankshaft from one side while turning it from the other
side. The turning insures that during this sequence the crankshaft does not become wedged against the front
portion of the connecting rods (20). The far side bearing (15) will remain in the crankcase (1). When free, the
crankshaft can be removed by hand. The opposite side crankshaft seal (14) will be removed by this proce-
dure. It is important that you turn the crankshaft (18) constantly while tapping from the opposite end to
avoid any binding. The crankshaft bearing (15) remains on the crankshaft as it is removed. If neces-
sary, use a bearing puller to remove the crankshaft bearing (15).
20. Remove the front portion of the connecting rods (20) and plunger base assembly (22) from the rear of the
pump by pulling straight out of the crankcase crosshead guides. Notice that the connecting rod (20) halves
are numbered or colored. Connecting rods must be positioned with their numbers or colors on the up-
per left-hand side, in the same numerical sequence as when they were removed.
21. Using a dowel and a rubber mallet, tap the oil seals (26) out from the rear of crankcase (1). 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 lips 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 the pin on opposite side of mark located on the crosshead.
On those pumps without mark on crosshead, drive out pin by tapping on tapered side of pin.
23. To remove the bearing (15) remaining in the crankcase (1), insert small end of Giant bearing tool (Tool-1) and
tap with a rubber mallet until bearing and seal (14) are completely removed. The bearing can only be re-
moved from the inside by inserting the Giant Bearing Tool through the opposite side of the crankcase.
The crosshead guide in the crankcase should be inspected for possible damage.
24. To reassemble, place the far bearing (15) in the crankcase (1) bearing housing and with the Giant Bearing tool
(Tool-1) as a driver, tap into the crankcase using a rubber mallet.
25. Insert the far side crankshaft oil seal (14) with the Giant Bearing Tool (Tool-1) making sure it is firmly seated
and well oiled. Always make sure that the crankshaft seal lip does not show signs of wear and that the garter
spring is firmly in place on the seal before reinserting into the pump. Replace the bearing cover (12) and o-ring
(13) and tighten securely.
Repair Instructions
P55W/P56W/P56W-HK/P56W-0011/P56W-0021/P56W-0121

11
Repair Instructions
P55W/P56W/P56W-HK/P56W-0011/P56W-0021/P56W-0121
Pump Mounting Selection Guide
Bushings
01056 - 22 mm Tapered H Bushing
Pulley & Sheaves
01055 - 9.75” Cast Iron - 2 gr.-AB Section
01061 - 7.75” Cast Iron 1 gr. - AB Section
01062 - 7.75” Cast Iron - 2 gr. - AB Section
Rails
01034 - Steel Box Rails
(L=9.25” x W=1.18” x H=1.62”)
01075 - Plated Steel Channel Rails
(L=9.00” x W=2.12” x H=2.50”)
26. Replace the front portion of 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 from marked side. The crosshead pin (23) should not extend beyond
either side of the crosshead (22) in order to prevent damage to the crosshead bore of the crankcase
(1).
27. Place each crosshead/ plunger assembly into the pump making sure that all of the parts are well oiled before
insertion into the crankcase (1). Notice that the connecting rod (20) halves are numbered or colored.
Connecting rods must be positioned with their numbers or colors on the upper left-hand side, in the
same numerical sequence as when they were removed.
28. Replace near side bearing (15) on crankshaft by using the Giant Bearing Tool (Tool-1) and mallet to tap into
place. Take the crankshaft (18) end with the bearing (15) and insert the other end through the bearing hous-
ing and tap with a rubber mallet until the bearing is seated.
29. When reassembling the connecting rods (20), note that the connecting rod halves are numbered or colored
and that the numbers or colors must be matched and aligned. Torque the connecting rod bolts to 125-150 in.-
lbs.
30. Insert the near side crankshaft oil seal (14) with the Giant Bearing Tool (Tool-1) making sure it is firmly seated
and well oiled. Replace the bearing cover (12) and o-ring (13) and tighten securely.
See instructions above for re-installing fluid end onto the gear end.
31. Fill the crankcase (1) with 12.5 oz. (370 mL) of Giant Industries’ oil (p/n 01154) and check the oil level with the
dipstick (5). Proper level is center of two lines. Reinstall the pump into your system.
Preventative Maintenance Check-List & Recommended Spare Parts List
Check Daily Weekly 50hrs Every Every Every
500 hrs 1500 hrs 3000 hrs
Oil Level/Quality X
Oil Leaks X
Water Leaks X
Belts, Pulley X
Plumbing X
Recommended Spare Parts
Oil Change p/n 1154 X X
Plunger Packing Kits (1 kit/pump) X
(See page 6 for kit list)
Valve Assembly Kit (1 kit/pump) X
(See page 6 for kit list)
Oil Seal Kit (1 kit/pump) X
(See page 6 for kit list)