Giant P540 User manual

Contents:
Installation Instructions: page 2
Pump Specications: page 3
Exploded View: page 4
Parts List/Kits: page 5
Torque Specications: page 5
Repair Instructions: page 6
Trouble Shooting Chart: page 7
Recommended Spare Parts List: page 7
Dimensions: back page
Warranty Information back page
Models
P540 and P541
Triplex Ceramic
Plunger Pump
Operating Instructions/
Repair and Service Manual
Updated 09/21

2
Finally, remember that high pressure operation in a pump system has many advantages. But, if it is
used carelessly and without regard to its potential hazard, it can cause serious injury.
Check oil level prior to starting and ensure
trouble-free water supply.
If there is a danger of frost,
the water in the pump and in the pump ttings
(particularly the unloader valve) must be
emptied. The second discharge port can also
be used and the pump run “dry” for 1-2 minutes
for this purpose.
Oil: Use only 54.1 ounces (1.6 litres) of SAE
80-90W gear oil (p/n 01154).
Initial oil change after 50 operating hours and
then every 1000 hours, after 1 year if used less.
Caution: When operating in damp places or
with high temperature uctuations, oil must be
changed immediately (should condensation or
frothy oil occur in the gear case).
NPSH values must be observed.
Max. input pressure 145 PSI (10 bar), max.
suction head -4.4 PSI (-0.3 bar). Make
sure that the suction pulsation is su󰀩ciently
dampened - water column resonance must be
avoided.
If the pump is not used for a
long period of time, it is possible the seals (22
& 23) could become hard or brittle thus causing
the pump to leak when put into operation.
If this is the case, we recommend these seals
be replaced every 4 years.
Safety Rules
A safety valve is to be installed in accordance
with the guidelines for liquid spraying units
so that the admissible operating pressure
cannot be exceeded by more than 10%. Pump
operation without a safety valve as well as
any excess in temperature or speed limits
automatically voids the warranty.
When the pump is in operation, the drive shaft
end and the coupling must be enclosed by a
protective cover or a coupling bell.
Pressure in the discharge line and pump must
be at zero before any maintenance to the pump
takes place. Shut off suction line.
Disconnect fuses to ensure that the driving mo-
tor does not get switched on accidently.
Make sure that all parts on the pressure side
of the unit are vented before starting the pump.
In order to prevent air, or an air-water-mixture
being absorbed and to prevent cavitation oc-
curring, the pump NPSHR (=suction head) and
water temperature must be respected.
Cavitation and/or compression of gases lead
to uncontrollable pressure-kicks which can
ruin pump and unit parts and also be dan-
gerous to the operator or anyone standing
nearby.
GIANT Plunger Pumps are suitable for pumping
clean water and other non-aggressive or non-
abrasive media with a specific weight similar to
water.
Before pumping other liquids - especially
ammable, explosive and toxic media - the
pump manufacturer must be consulted with
regard to the resistance of the pump mate-
rial. It is the responsiblity of the equipment
manufaturer and/or operator to ensure that
all pertinent safety regulations are adhered
to.
Important!
Important!
INSTALLATION INSTRUCTIONS - P540 AND P541

3
U.S. ......................... (Metric)
Maximum Volume .........................................35.4 GPM ............... (134 LPM)
Maximum Discharge Pressure .....................1450 PSI ................. (100 bar)
Speed ............................................................................................ 1450 RPM
Power Required............................................35.3 HP.................... 26.3 kW
Inlet Pressure ...............................................-4.35 to145 PSI ...... -0.3 to 10 bar
Plunger Diameter..........................................1.57” ........................ 40 mm
Crankshft Stroke...........................................1.02” ........................ 26 mm
Crankshaft Diameter...................................................................... 30 mm
Crankshaft Mounting ..................................................................... Either side
Shaft Rotation................................................................................ Top of pulley towards manifold
Temperature of Pumped Fluids ....................Up to 104 oF ............ (40 oC)
Inlet Ports ...................................................................................... (2) 1-1/2” BSP
Discharge Ports............................................................................. (2) 1” BSP
Weight (P540)...............................................91.5 lbs. .................. (41.5 kg)
Weight (P451)...............................................84.9 lbs.................... (38.5 kg)
Crankcase Oil Capacity................................54.1 . oz ................. (1.6 liter)
Fluid End Material (P540).............................................................. Forged Brass
Fluid End Material (P541).............................................................. Nickel-Plated Spheroidal Cast Iron
NPSHR.........................................................26.9 ft. of head ........ 8.2 mWs
Specications
Models P540 and P541
Consult the factory for special requirements that must be met if the pump is to
operate beyond one or more of the limits specied above.
PULLEY 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.
2. The desired pressure is achieved by selecting
the correct nozzle size that corresponds with the
pump GPM.
HORSEPOWER INFORMATION
Horsepower ratings shown are the power re-
quirements for the pump. Gas engine power
outputs must be approximately twice the pump
power requirements shown above.
We recommend that a 1.15 service factor be speci-
ed when selecting an electric motor as the power
source. To compute specic pump horsepower
requirements, use the following formula:
(GPM X PSI) / 1450 = HP
P540 and P541 Horsepower Requirements
RPM GPM 500
PSI
750
PSI
1000
PSI
1250
PSI
1450
PSI
725 17.7 6.1 9.2 12.2 15.3 17.7
800 19.5 6.7 10.1 13.5 16.8 19.5
900 22.0 7.6 11.4 15.2 19.0 22.0
1000 24.4 8.4 12.6 16.8 21.0 24.4
1200 29.3 10.1 15.2 20.2 25.3 29.3
1450 35.4 12.2 18.3 24.4 30.5 35.4
Materials Used:
Plungers ....... Solid Ceramic Oxide
Valves ........... Stainless Steel
Seals............. Nitrile with Fabric Reinforcing
Gear End ...... Die-Cast Aluminum

4
EXPLODED VIEW - P540 and P541

5
ITEM PART DESCRIPTION QTY.
1 04405 Crankcase 1
2 04234 Oil Dipstick Assembly 1
3 04406 Crankcase Cover 1
4 04407 O-Ring 1
5 07109 Oil Drain Plug 1
5A 06015 Gasket for Oil Drain Plug 1
6 01010 Screw 4
6A 01011-0400 Spring Washer 4
7 04408 Bearing Cover 1
7A 08490 Oil Sight Glass 1
7B 08492 O-Ring 1
7C 04237 Clip Ring 1
8A 04409 Shim 1-3
8B 04410 Shim 1
9 04411 O-Ring 2
10 07114 Screw with Washer 8
10A 01011 Spring Washer 8
11 04238 Radial Shaft Seal 1
12 04239 Tapered Roller Bearing 2
13 04425 Crankshaft 1
14 04241 Fitting Key 1
15 04242 Connecting Rod Assembly 3
16 04427 Plunger Assembly 3
16A 04428 Plunger Pipe 3
16B 08399 Tension Screw 3
16C 07023 O-Ring 3
16D 07203 Support Ring 3
16E 07258 Steel Washer 3
17 04412 Crosshead w/Plunger Base 3
17A 07124 Crosshead Pin 3
19 07624 Radial Shaft Seal 3
19A 04413 Distance Ring 3
ITEM PART DESCRIPTION QTY.
20 04429 Seal Retainer 3
21 06560 O-Ring 3
22 05308 Sleeve 6
23 04430 Grooved Ring 3
23A 04431 Scraper 3
24 04432 Sleeve Support Ring 3
25 04433 Drip Return Ring 3
26 04434 Valve Casing (P540) 1
26 04458 Valve Casing (P541) 1
32 04435 Plug 6
33 12055 O-Ring 6
34 05546 Cap Screw 8
34A 04417 Cap 2
36 12249 Plug, 1” BSP 1
36A 13372-0300 Copper Ring 1
37 04436 Plug, 1-1/2” BSP 1
46 04437 Inlet Valve Assembly 3
46A 13304 Valve Seat 3
46B 12055 O-Ring 3
46C 13306 Valve Plate 3
46D 13307 Inlet Valve Spring 3
46E 13308 Spring Tension Cap 3
47 04438 Discharge Valve Assembly 3
47A 13304 Valve Seat 3
47B 12055 O-Ring 3
47C 13306 Valve Plate 3
47D 04439 Discharge Valve Spring 3
47E 13308 Spring Tension Cap 3
04400 Gear Assy. (1-19, 34)
04441 Manifold Assy. (20-47 w/out 34)
04442 Manifold Assy. (20-47 w/out 34)
P540 and P541 SPARE PARTS LIST
P540 and P541 REPAIR KITS
Discharge Valve Assembly Kit - #09778
Item Part # Description Qty
33 12055 O-Ring 3
47 04438 Valve Assembly 3
Oil Seal Kit - #09755
Item Part # Description Qty
19 07624 Radial Shaft Seal 3
Plunger Packing Kit - #09776
Item Part # Description Qty
21 06560 O-Ring 3
22 05308 Sleeve 6
23 04430 Grooved Seal 3
23A 04431 Scraper 3
Inlet Valve Assembly Kit - #09777
Item Part # Description Qty
33 12055 O-Ring 3
46 04437 Inlet Valve Assembly 3
TORQUE SPECIFICATIONS - P540 and P540
Position Item # Description Lubrication Info Torque Amount
5 07109 Oil Drain Plug 22 ft.-lbs. (40 Nm)
6 01010 Screw 110 in.-lbs. (12.5 Nm)
10 07114 Screw with Washer 132 in.-lbs. (15 Nm)
15 04242 Connecting Rod Assembly 97 in.-lbs. (11 Nm)
16B 08399 Tension Screw Loctite 243 247 in.-lbs. (28 Nm)
32 04435 Plug 106 ft.-lbs. (145 Nm)
34 05546 Cap Screw 59 ft.-lbs. (80 Nm)

6
1. To Check Valves
Screw out plugs (32) with a socket wrench.
Remove the exposed spring tension cap (46E)
from the valve seat by pushing it sideways using
a screwdriver. Remove spring tension cap, valve
spring (46D) and valve plate (46C). Pull out valve
seat (46A) with a valve puller. Examine valve
components for wear and damage. Check O-
rings (46B). Replace worn parts.
Pay attention to the sequence of installation when
reassembling. New O-rings should be coated with
oil.
Tighten plungs (32) to 107 ft.-lbs. (145 Nm).
2. To Check Seals and Plunger Pipes
Remove hexagon socket screws (34) and pull o󰀨
valve casing (26) to the front. Pull seal retain-
ers (20) out of the valve casing (26) or crankcase
(1). Examine O-rings (21), grooved rings (23) and
scraper (23A).
Remove drip return rings (25), V-sleeves (22) and
support rings (24) from the valve casing. Check
that the bores in the leakage rings and the cor-
responding bores in the valve casing are free of
obstruction.
Check plunger surfaces (16A). Damaged sur-
faces cause accelerated seal wear. Lime and
other deposits on the plunger must be carefully
removed using a sharp knife. Be careful not to
damage plunger surfaces. If plunger pipe (16A)
is worn, remove tensioning screw (16B) with the
plunger. Examine and clean the plunger mounting
surface (17), check and mount the new plunger
pipe.
Lightly coat the threads of the tensioning screw
(16B) with Loctite and carefully tighten to 248
in.-lbs. (28 Nm). Glue must never come between
plunger pipe (16A) and centering sleeve (16F).
The plunger pipe should not be strained by ex-
tensive tightening of the tension screw or through
damage to the front surface as this can lead to
breakage.
When reassembling, insert scraper (23A) and
grooved ring (23) into seal retainer (20).
Carefully push the whole unit onto the ceramic
plunger (if necessary use the drip return ring to
hold the grooved ring in its seal retainer) and push
it down into the crankcase tting. Slide on drip re-
turn ring (25) with its V-prole facing upwards. Put
sleeve support ring (24) into the valve casing. Tilt
V-sleeve (22) into its tting. Then carefully press it
level using the at side of a screwdriver.
Be careful not to scratch the
valve casing.
Carefully push the whole pump head over the
ceramic plungers and against the crankcase.
Tighten hexagon socket screws (34) evenly in a
crosswise manner at 59 ft.-lbs. (80 Nm).
3. Drive
If oil leaks where the plunger (17) protrudes out of
the drive, gear seals (19) and plungers must be
examined and replaced as necessary.
Remove oil plug (5) and drain oil; remove crank-
case cover (3).
Remove valve casing (26), seal casing (21), seal
adaptors (20) as well as plunger pipes (16A) as
desribed in point 2.
Take off screws on connnecting rods (15), seper-
ate the back connecting rod half from the crank-
shaft and front connecting rod half by screwing a
screw into the center back bore on the connecting
rod.
Be careful not to mix up the connecting rod
halves.
Push conrod shaft as far as possible into the
crosshead guide.
Take off screws (10) and remove bearing covers
(7) with the help of a screwdriver.
Take out crankshaft carefully threading it through
the conrods (15), making sure not to bend the
conrods. Remove and dismantle conrods and
plungers (17) paying attention not to damage the
plungers.
Lever out gear seal (19) using a screwdriver.
To reinstall, press the gear seal (19) into the drive
casing first. Then insert conrods with plungers.
Thread in crankshaft. Mount bearing covers (7)
together with the taper roller bearing (12) and fix
with screws (10).
Mount bearing cover (8) and adjust clearance by
fitting shims (8A/8B) under the bearing cover (8)
to ensure the crankshaft turns easily without play
being felt.
Finally, mount conrod halves together and tighten
screws (15) at 97 in.-lbs. (11 Nm). Mount crank-
case cover (3) together with O-ring (4).
When remounting the valve casing, tighten hexa-
gon socket screws at 59 ft.-lbs. (80 Nm).
REPAIR INSTRUCTIONS - P540 and P541
Important!

7
PUMP SYSTEM MALFUNCTION
MALFUNCTION CAUSE REMEDY
The Pressure and/ Worn packing seals Replace packing seals
or the Delivery Broken valve spring Replace spring
Drops Belt slippage Tighten or Replace belt
Worn or Damaged nozzle Replace nozzle
Fouled discharge valve Clean valve assembly
Fouled inlet strainer Clean strainer
Worn or Damaged hose 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 High humidity Reduce oil change interval
Worn seals Replace seals
Noisy Operation Worn bearings Replace bearings, Rell crankcase
oil with recommended lubricant
Cavitation Check inlet lines for restrictions
and/or proper sizing
Rough/Pulsating Worn packing Replace packing
Operation with Inlet restriction Check system for stoppage, air
Pressure Drop leaks, correctly sized inlet
plumbing to pump
Accumulator pressure Recharge/Replace accumulator
Unloader Check for proper operation
Cavitation Check inlet lines for restrictions
and/or proper size
Pump Pressure as Restricted discharge plumbing Re-size discharge plumbing to Flow
Rated, Pressure Rate of Pump
Drop at Gun
Excessive Worn plungers Replace plungers
Leakage Worn packing/seals Adjust or Replace packing seals
Excessive vacuum Reduce suction vacuum
Cracked plungers Replace plungers
Inlet pressure too high Reduce inlet pressure
High Crankcase Wrong Grade of oil Giant oil is recommended
Temperature Improper amount of oil in crankcase Adjust oil level to proper amount
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 (54 ounces) p/n 1154 X X
Seal Spare Parts (1 kit/pump) X
(See page 5 for kit list)
Oil Seal Kit (1 kit/pump) X
(See page 5 for kit lit)
Valve Spare Parts (1 kit/pump) X
(See page 5 for kit list)

GIANT INDUSTRIES, INC., 900 N. Westwood Ave., P.O. Box 3187, Toledo, Ohio 43607
PHONE [phone], FAX [phone], www.giantpumps.com
 Copyright 2021 Giant Industries, Inc.
09/21 P540_P541.indd
DIMENSIONS - P540 and P541 - 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. 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 modications made by the customer or third party.
6. The operation of pumps and or accessories exceeding the specications 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 www.P65Warnings.ca.gov