Giant P57 User manual

Models
P57 & P57-0011
Triplex Ceramic
Plunger Pump
Operating Instructions/
Repair and Service
Manual
Contents:
Installation Instructions: page 2
Pump Specifications: page 3
Exploded View: page 4
Parts List / Kits: page 5
Torque Specifications: page 5
Trouble Shooting: page 6
Pump Mounting Selection Guide: page 6
Recommended Maintenance Schedule: page 6
Repair Instructions: page 7
Dimensions: back page
Warranty Information: back page
Updated 7/07

INSTALLATION INSTRUCTIONS
4. Use of a dampener is necessary to minimize
pulsation at drive elements, plumbing, connec-
tions, and other system areas. The use of a
dampener with Giant Industries, Inc. pumps is
optional, although recommended by Giant
Industries, Inc. to further reduce system pulsa-
tion. Dampeners can also reduce the severity of
pressure spikes that occur in systems using a
shut-off gun. A dampener must be positioned
downstream from the unloader.
5. Crankshaft rotation on Giant Industries, Inc.
pumps should be made in the direction desig-
nated by the arrows on the pump crankcase.
Reverse rotation may be safely achieved by
following a few guidelines available upon
request from Giant Industries, Inc. Required
horsepower for system operation can be ob-
tained from the chart on page 3.
6. Before beginning operation of your pumping
system, remember: Check that the crankcase
and seal areas have been properly lubricated per
recommended schedules. Do not run the pump
dry for extended periods of time. Cavitation will
result in severe damage. Always remember to
check that all plumbing valves are open and that
pumped media can flow freely to the inlet of the
pump.
IMPORTANT OPERATING CONDITIONS
Failure to comply with any of these conditions invalidates the warranty.
2. Pump operation must not exceed rated
pressure, volume, or RPM. A pressure relief
device must be installed in the discharge of the
system.
3. Acids, alkalines, or abrasive fluids cannot be
pumped unless approval in writing is obtained
before operation from Giant Industries, Inc.
4. Run the pump dry approximately 10 seconds
to drain the water before exposure to freezing
temperatures.
1. Prior to initial operation, add oil to the
crankcase so that oil level is between the two
lines on the oil dipstick. DO NOT OVERFILL.
Use Giant 20W-50 oil (p/n 01153) or use
SAE 80-90W Industrial Gear Lube oil
(p/n 01154),
Crankcase oil should be changed after the
first 50 hours of operation, then at regular
intervals of 500 hours or less depending on
operating conditions.
Installation of the Giant Industries, Inc.,
pump is not a complicated procedure, but
there are some basic steps common to all
pumps. The following information is to be
considered as a general outline for installa-
tion. If you have unique requirements, please
contact Giant Industries, Inc. or your local
distributor for assistance.
1. The pump should be installed flat on a base to
a maximum of a 15 degree angle of inclination
to ensure optimum lubrication.
2. The inlet to the pump should be sized for the
flow rate of the pump with no unnecessary
restrictions that can cause cavitation. Teflon
tape should be used to seal all joints. If pumps
are to be operated at temperatures in excess of
1600F, it is important to insure a positive head
to the pump to prevent cavitation.
3. The discharge plumbing from the pump
should be properly sized to the flow rate to
prevent line pressure loss to the work area. It is
essential to provide a safety bypass valve
between the pump and the work area to protect
the pump from pressure spikes in the event of a
blockage or the use of a shut-off gun.
Finally,rememberthathighpressureoperationinapumpsystemhasmanyadvantages. But,ifitisusedcarelessly
and without regard to its potential hazard, it can cause serious injury.
2

U.S. ..................................... Metric
Flow.............................................................. 1.3 GPM ............................. 5.1 Liters/min.
Discharge Pressure (Continuous) ................. 5000 PSI ............................. 350 Bar
Discharge Pressure (Intermittent)................. 6525 PSI ............................. 450 Bar
Max. Inlet Pressure....................................... 145 PSI ............................... 10 Bar
Max. Crankshaft Speed .............................................................................. 1420 RPM
Plunger Diameter.......................................... 0.47” ................................... 12 mm
Stroke............................................................ 0.56” ................................... 18.1 mm
Crankcase Oil Capacity ................................ 15.2 fl.oz............................. 0.45 Liters
Max. Temperature of Pumped Fluids ........... 160 oF.................................. 70 oC
Inlet Ports ................................................................................................... (2) 1/2" BSP
Discharge Ports........................................................................................... (2) 3/8" BSP
Crankshaft Mounting.................................................................................. Either
Shaft Rotation............................................... Top of Pulley Towards Fluid End
Weight........................................................... 17.2 lbs. .............................. 7.8 Kg.
Crankshaft Diameter..................................... 0.87” ................................... 22mm
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.
Specifications
Models P57 & P57-0011
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 require-
ments for the pump. Gas engine power outputs must
be approximately twice the pump power require-
ments 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:
GPM X PSI =hp
1460
3
P57 PULLEY SELECTION & HORSEPOWER REQUIREMENTS
PUMP
PULLEY RPM GPM 3000 PSI 4000 PSI 5000 PSI 6525 PSI*
7.75" 500 0.5 1.0 1.4 1.7 2.3
7.75" 750 0.7 1.4 1.9 2.4 3.2
7.75" 1000 0.9 1.9 2.5 3.1 4.1
7.75" 1250 1.1 2.3 3.0 3.8 5.0
7.75" 1420 1.3 2.7 3.6 4.5 5.9

Exploded View - P57 & P57-0011
4

P57 & P57-0011 SPARE PARTS LIST
ITEM PART DESCRIPTION QTY.
29 12226 Manifold 1
30 12130 Pressure Ring 3
31 08354 Grooved Seal (P57) 3
31 07391-0010 Grooved Seal, Viton (P57-0011) 3
32 07941 Support Ring 3
33 12132 Pressure Spring 3
33A 12133 Support Disc I 3
33B 12134 Support Disc II 3
34 07907 Spring Tension Disc 6
35 07906-0100 Valve Spring 6
36 07491 Valve Plate 6
37 07849 Valve Seat 6
38 07853 O-Ring (P57) 6
38 07853-0001 O-Ring, Viton (P57-0011) 6
39 07940 Suction Valve Retainer 3
40 07212 O-Ring (P57) 3
40 07212-0001 O-Ring, Viton (P57-0011) 3
41 12135 Plug, Inlet 3
42 07214 O-Ring (P57) 3
42 07214-0001 O-Ring, Viton (P57-0011) 3
43 12136 Plug, Outlet 3
44 07913 O-Ring (P57) 3
44 07913-0001 O-Ring, Viton (P57-0001) 3
45 07215 Stud Bolt 4
46 08040 Hex Nut 4
47 08041 Spring Ring 4
52 12250 Plug, 1/2” BSP, S.S. 1
53 12138 Plug, 3/8” BSP, S.S. 1
ITEM PART DESCRIPTION QTY.
1 07180 Crankcase 1
2 07181 Oil Fill Plug Assembly 1
2A 07182 Gasket 1
3 07183 Cover, Crankcase 1
4 07184 O-Ring, Crankcase Cover 1
5 07185 Oil Dip Stick Assembly 1
6 01009 O-Ring, Dip Stick 1
7 07186 Oil Sight Glass Assembly 1
9 07188 Screw, Crankcase Cover 4
10 07223-0100 Spring Washer 4
11 07190 Oil Drain Plug Assembly 1
11A 07191 Gasket 1
12 13402 Bearing Cover 2
13 07193 O-Ring, Bearing Cover 2
14 01166 Radial Shaft Seal 2
15 01086 Bearing 2
16 07114 Hex Screw with Washer 6
17 05023 Shaft Protector 1
18 12128 Crankshaft 1
19 01024 Woodruff Key 1
20 07199 Connecting Rod 3
21 01027 Screw with Washer 6
22 07396 Plunger Assy. 3
23 01031 Crosshead Pin 3
25 13403 Flinger 3
26 08026 Radial Shaft Seal 3
26A 13346 Spacer Sleeve 3
28 07207 Centering Sleeve 2
P57 & P57-0011 REPAIR KITS
Valve Assembly Kit #09315 (P57)
Item Part # Description Qty.
34 07907 Spring Tension Disc 6
35 07906-0010 Valve Spring 6
36 07491 Valve Plate 6
37 07849 Valve Seat 6
38 07853 O-Ring 6
40 07212 O-Ring 3
42 07214 O-Ring 3
44 07913 O-Ring 3
Oil Seal Kit #09314 (P57 & P57-0011)
Item Part # Description Qty.
25 13403 Flinger 3
26 08026 Radial Shaft Seal 3
Plunger Packing Kit #09313 (P57)
Item Part # Description Qty.
31 08354 Grooved Seal 3
32 07941 Support Ring 3
40 07212 O-Ring 3
42 07214 O-Ring 3
Plunger Packing Kit #09313-0011 (P57-0011)
Item Part # Description Qty.
31 07391-0010 Grooved SealAssy. 3
32 07941 Support Ring 3
40 07212-0001 O-Ring,Viton 3
42 07214-0001 O-Ring,Viton 3
5
Position Item# Description Torque Amount
21 01027 Screw with Washer 133 (in-lbs.)
41 12135 Plug, Inlet 52 (ft.-lbs.)
43 12136 Plug, Discharge 52 (ft.-lbs.)
46 08040 Nut, Stud 35 (ft-lbs)
P57 & P57-0011 TORQUE SPECIFICATIONS

PUMP SYSTEM MALFUNCTION
PUMP SYSTEM MALFUNCTIONS
MALFUNCTION CAUSE REMED
Y
ThePressureand/
or the Deliver
y
Dro
p
sWorn packing seals Replace packing seals
Broken valve springs Replace springs
Belt slippage Tighten or Replace belt
Worn or Damaged nozzle Replace nozzle
Fouled discharge valve Clean valve assembly
Worn or Plugged relief valve on pump Clean, Reset, and Replace
wornparts
Cavitations Check suction lines on inlet
of pumpfor restrictions
Unloader Check for proper operation
Water in Crankcase Hi
g
h Humidit
y
Reduce oil chan
g
e intervals
Worn Seals Replace seals
Nois
y
Operatin
g
Wornbearin
g
s Replace bearin
g
s, Refill
crankcase oil with recommended
lubricant
Cavitation Check inlet lines for restrictions
and/or proper sizing
Rough/Pulsating
Operationwith
Pressure Dro
p
Worn packing Replace packing
Inlet restriction Check systemfor stoppage
air leaks, correctly sized
inlet plumbing topump
Accumulator pressure Recharge/Replace accumulator
Unloader Check for proper operation
Cavitation Check inlet lines for restrictions
and/or proper size
Pump Pressureas
Drop at gun Rated,
Pressure
Restricted discharge plumbing Re-size discharge plumbing to flow
rate of pump
Excessive
Leaka
g
eWorn plungers Replace plungers
Worn packing/seals
A
d
j
ust or Replace packin
g
seals
Excessive vacuum Reduce suction vacuum
Cracked plungers Replace plungers
Inlet pressure toohigh Reduceinlet pressure
HighCrankcase
Tem
p
erature Wrong Grade of Oil Giant oil is recommended
Improper amount of oil in crankcase Adjust oil level to proper amount
6
Pump Mounting Selection Guide
Bushings
01056 - 22 mm Tapered H Bushing
Pulley & Sheaves
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”)
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 (1 Quart) p/n 01153 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)

REPAIR INSTRUCTIONS - P57 & P57-0011
CAUTION
The stainless steel valve plugs (41 and 43) can seize (when being removed from the manifold). To release tension
beforehand, strike the plugs 1 to 2 times with a steel hammer on the top (before removing them). When replacing them,
make sure that the threads are coated with antiseize, e.g., ProPack550.
To Check Suction and Discharge Valves
Inlet Valves
1. Using a socket wrench, carefully remove valve plugs (41 and 43). Take out the suction valve adaptor (39) along with the
suction valve assembly (34-38).
2. Using a soft tool, push the valve assembly (34-38) out of the suction valve adaptor (39).
3. Replace o-rings (38, 40 and 42). Replace valve parts (34-37).
4. Carefully replace the valve plugs and tighten to 52 ft-lbs (70 NM).
Discharge Valves
5. Remove the valve plugs (43). Remove the exposed spring tension cap (34), valve spring (35) and valve plate (36).
6. Using a 12mm (diameter) valve puller, take out the valve seat (37).
7. Replace o-rings (38 and 44). Replace valve parts 34-37.
8. Carefully replace and tighten valve plugs to 52 ft-lbs (70 NM).
To Check Seals and Plunger Pipe
1. Carefully remove the valve plugs (41). Remove stud nuts (46) and washer (47) from the manifold (29). By pulling it out
towards the front. Remove the manifold from the plungers (22).
2. Take out he suction valve adaptor (39), tension spring (33), support discs (I and II) and seal unit (30, 31 and 32).
3. Check the surface of the plungers (22). Any damaged surfaces will cause accelerated wear on the seals. If the plunger
(22) is worn, the complete plunger must be changed - see the section below. The ceramic pipe alone cannot be changed
due to reasons of precision.
4. Check and clean the pressure ring and reinstall into the manifold (29).
5. Reinstall the support ring (32). Prior to replacing the seal assembly (31), grease the new seals.
6. Replace the remaining parts into the manifold (29) in the order that they were removed.
7. Evenly tighten the valve casing with the stud nuts (46) to 35 ft-lbs (47.5 NM).
To Check Plungers and Crankcase
1. If oil leaks at plunger outlet (22), the oil seal (26) and the plungers have to examined (and replaced, if necessary). After re-
moving the valve casing (29) and its components, drain the oil and remove crankcase cover (3) and bearing cover (12).
2. Remove the connecting rod screws (21) and push the outer connecting rod halves as far as possible into the crosshead guides.
Important! The connecting rods are marked for identification. Do not twist the connecting rod halves. Connecting
rods are to be fitted back onto the crankshaft journals in their exact original position.
3. While slightly turning, hit out (using a rubber hammer) the crankshaft (18) to one side. Either press out the second bearing in
the crankcase or carefully hit it out with a soft tool.
Important! Do not bend the connecting rod shanks. Check the crankshaft, connecting rod surfaces as well as the shaft
seals (26). Rough surfaces indicate a problem with lubrication and/or possible rough running of the pump. If you
suspect that the pump has been running under cavitation or heavy pulsations, make improvements on the inlet and/or
discharge connections to and from the pump.
4. If oil has been leaking through the plunger base oil seals (26), remove them by pushing them out from the backside with a
socket wrench. With the seal lip facing forward, replace them into the crankcase (1).
To Reassemble
1. Replace the front halves of the connecting rod (22) and plunger assembly (22). Make sure that they are in the same
position and orientation.
2. Using a soft tool, press in one roller bearing until it lies level with the edge of the bearing hole. Mount the other bearing onto
the crankshaft.
3. Carefully press in the crankshaft through the opposite bearing hole being particularly careful with the journals.
4. Install radial shaft seal (15), bearing cover (12) and o-ring (13).
5. Replace the back-halves of the connecting rods (to their original position and orientation) and tighten to 133 in-lbs (15
NM).
Important! After assembly has been completed, the crankshaft should turn easily (with very little movement).
6. Replace the flinger (25) on the plunger (22)
7. Replace the back cover (3) o-ring (4), manifold (29) and its contents. Tighten the nuts (46) to 35 ft-lbs (47.5 NM).
8. Make sue Fill the crankcase (1) with the proper amount of oil.
NOTE: Contact Giant Industries for Service School Information. Phone: [phone]
7

P57 & P57-0011 PUMP DIMENSIONS (MM)
GIANT INDUSTRIES, INC., 900 N. Westwood Ave., P.O. Box 3187, Toledo, Ohio 43607
PHONE [phone], FAX [phone], www.giantpumps.com
 Copyright 2007 Giant Industries, Inc.
07/07 P57.PMD
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
warrantedforfive years from the date ofshipmentfor 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
workmanshiporfailureofmaterial. AReturnedGoodsAuthorization(R.G.A.)numberandcompleted
warranty evaluation form is required prior to the return to Giant Industries of all products under
warranty consideration. Call (419)-531-4600 or fax [phone] to obtain an R.G.A. number.
Repair or replacement of defective products as provided is the sole and exclusive remedy provided
hereunderandtheMANUFACTURERSHALL NOTBE LIABLEFORFURTHERLOSS,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.