Giant Water Pump P57 User Manual

Triplex Ceramic  
Plunger Pump  
Operating Instructions/  
Repair and Service  
Manual  
Models  
P57 & P57-0011  
Contents:  
Installation Instructions:  
Pump Specifications:  
Exploded View:  
Parts List / Kits:  
Torque Specifications:  
Trouble Shooting:  
page 2  
page 3  
page 4  
page 5  
page 5  
page 6  
page 6  
Pump Mounting Selection Guide:  
Recommended Maintenance Schedule:  
Repair Instructions:  
page 6  
page 7  
Updated 7/07  
Dimensions:  
Warranty Information:  
back page  
back page  
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Specifications  
Models P57 & P57-0011  
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.  
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  
P57 PULLEY SELECTION & HORSEPOWER REQUIREMENTS  
PUMP  
PULLEY  
RPM GPM 3000 PSI 4000 PSI 5000 PSI 6525 PSI*  
7.75"  
7.75"  
7.75"  
7.75"  
7.75"  
500 0.5  
750 0.7  
1000 0.9  
1250 1.1  
1420 1.3  
1.0  
1.4  
1.9  
2.3  
2.7  
1.4  
1.9  
2.5  
3.0  
3.6  
1.7  
2.4  
3.1  
3.8  
4.5  
2.3  
3.2  
4.1  
5.0  
5.9  
3
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Exploded View - P57 & P57-0011  
4
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P57 & P57-0011 SPARE PARTS LIST  
ITEM PART  
DESCRIPTION  
Crankcase  
Oil Fill Plug Assembly  
Gasket  
Cover, Crankcase  
O-Ring, Crankcase Cover  
Oil Dip Stick Assembly  
O-Ring, Dip Stick  
Oil Sight Glass Assembly  
Screw, Crankcase Cover  
QTY.  
1
ITEM PART  
DESCRIPTION  
Manifold  
Pressure Ring  
Grooved Seal (P57)  
QTY.  
1
2
2A  
3
4
5
6
7
9
07180  
07181  
07182  
07183  
07184  
07185  
01009  
07186  
07188  
29  
30  
31  
31  
32  
33  
33A  
33B  
34  
35  
36  
37  
38  
38  
39  
40  
40  
41  
42  
42  
43  
44  
44  
45  
46  
47  
52  
53  
12226  
12130  
08354  
1
3
3
1
1
1
1
1
1
1
4
4
1
1
2
2
2
2
6
1
1
1
3
6
3
3
3
07391-0010 Grooved Seal, Viton (P57-0011) 3  
07941  
12132  
12133  
12134  
07907  
Support Ring  
3
3
3
3
6
6
6
6
6
6
3
3
3
3
3
3
3
3
3
4
4
4
1
1
Pressure Spring  
Support Disc I  
Support Disc II  
Spring Tension Disc  
10  
11  
11A  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
25  
26  
26A  
28  
07223-0100 Spring Washer  
07906-0100 Valve Spring  
07190  
07191  
13402  
07193  
01166  
01086  
07114  
05023  
12128  
01024  
07199  
01027  
07396  
01031  
13403  
08026  
13346  
07207  
Oil Drain Plug Assembly  
Gasket  
07491  
07849  
07853  
Valve Plate  
Valve Seat  
O-Ring (P57)  
Bearing Cover  
O-Ring, Bearing Cover  
Radial Shaft Seal  
Bearing  
Hex Screw with Washer  
Shaft Protector  
Crankshaft  
Woodruff Key  
Connecting Rod  
Screw with Washer  
Plunger Assy.  
Crosshead Pin  
Flinger  
Radial Shaft Seal  
Spacer Sleeve  
Centering Sleeve  
07853-0001 O-Ring, Viton (P57-0011)  
07940  
07212  
07212-0001 O-Ring, Viton (P57-0011)  
12135  
07214  
07214-0001 O-Ring, Viton (P57-0011)  
12136  
07913  
Suction Valve Retainer  
O-Ring (P57)  
Plug, Inlet  
O-Ring (P57)  
Plug, Outlet  
O-Ring (P57)  
07913-0001 O-Ring, Viton (P57-0001)  
07215  
08040  
08041  
12250  
12138  
Stud Bolt  
Hex Nut  
Spring Ring  
Plug, 1/2” BSP, S.S.  
Plug, 3/8” BSP, S.S.  
3
3
2
P57 & P57-0011 REPAIR KITS  
Plunger Packing Kit #09313 (P57)  
Valve Assembly Kit #09315 (P57)  
Item Part #  
Description  
Grooved Seal  
Support Ring  
O-Ring  
Qty.  
3
3
3
3
Item Part #  
Description  
Spring Tension Disc  
Qty.  
6
6
6
6
6
3
3
3
31  
32  
40  
42  
08354  
07941  
07212  
07214  
34  
35  
36  
37  
38  
40  
42  
44  
07907  
07906-0010 Valve Spring  
07491  
07849  
07853  
07212  
07214  
07913  
Valve Plate  
Valve Seat  
O-Ring  
O-Ring  
O-Ring  
O-Ring  
Plunger Packing Kit #09313-0011 (P57-0011)  
Item Part #  
Description  
07391-0010 Grooved Seal Assy.  
07941 Support Ring  
07212-0001 O-Ring, Viton  
07214-0001 O-Ring, Viton  
Qty.  
3
3
3
3
31  
32  
40  
42  
O-Ring  
Oil Seal Kit #09314 (P57 & P57-0011)  
Item Part #  
Description  
Flinger  
Radial Shaft Seal  
Qty.  
3
3
25  
26  
13403  
08026  
P57 & P57-0011 TORQUE SPECIFICATIONS  
Position  
Item#  
01027  
12135  
12136  
08040  
Description  
Screw with Washer  
Plug, Inlet  
Plug, Discharge  
Nut, Stud  
Torque Amount  
133 (in-lbs.)  
52 (ft.-lbs.)  
21  
41  
43  
46  
52 (ft.-lbs.)  
35 (ft-lbs)  
5
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PUMP SYSTEM MALFUNCTION  
PUMP SYSTEM MALFUNCTIONS  
Pump Mounting Selection Guide  
MALFUNCTION  
CAUSE  
REMEDY  
The Pressure and/  
Worn packing seals  
Replace packing seals  
or the DeliveryDrops  
Bushings  
01056 - 22 mm Tapered H Bushing  
Broken valve springs  
Belt slippage  
Worn or Damaged nozzle  
Fouled discharge valve  
Replace springs  
Tighten or Replace belt  
Replace nozzle  
Clean valve assembly  
Worn or Plugged relief valve on pump Clean, Reset, and Replace  
worn parts  
Pulley & Sheaves  
01061 - 7.75” Cast Iron 1 gr. - AB  
Section  
Cavitations  
Check suction lines on inlet  
of pump for restrictions  
Unloader  
Check for proper operation  
01062 - 7.75” Cast Iron - 2 gr. - AB  
Section  
Water in Crankcase  
NoisyOperating  
High Humidity  
Worn Seals  
Reduce oil change intervals  
Replace seals  
Worn bearings  
Cavitation  
Replace bearings, Refill  
crankcase oil with recommended  
lubricant  
Check inlet lines for restrictions  
and/or proper sizing  
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”)  
Rough/Pulsating  
Operation with  
Pressure Drop  
Worn packing  
Inlet restriction  
Accumulator pressure  
Replace packing  
Check system for stoppage  
air leaks, correctly sized  
inlet plumbing to pump  
Recharge/Replace accumulator  
Unloader  
Cavitation  
Check for proper operation  
Check inlet lines for restrictions  
and/or proper size  
Pump Pressure as  
Drop at gun Rated,  
Pressure  
Restricted discharge plumbing  
Re-size discharge plumbing to flow  
rate of pump  
Excessive  
Leakage  
Worn plungers  
Replace plungers  
Worn packing/seals  
Adjust or Replace packingseals  
Excessive vacuum  
Cracked plungers  
Reduce suction vacuum  
Replace plungers  
Inlet pressure too high  
Reduce inlet pressure  
High Crankcase  
Temperature  
Wrong Grade of Oil  
Giant oil is recommended  
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  
500 hrs  
Every  
1500 hrs  
Every  
3000 hrs  
Oil Level/Quality  
Oil Leaks  
Water Leaks  
Belts, Pulley  
Plumbing  
X
X
X
X
X
Recommended Spare Parts  
Oil Change (1 Quart) p/n 01153  
Seal Spare Parts (1 kit/pump)  
(See page 5 for kit list)  
X
X
X
X
Oil Seal Kit (1 kit/pump)  
(See page 5 for kit lit)  
Valve Spare Parts (1 kit/pump)  
(See page 5 for kit list)  
X
6
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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: (419)-531-4600  
7
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P57 & P57-0011 PUMP DIMENSIONS (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. 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  
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  
Copyright 2007 Giant Industries, Inc.  
07/07 P57.PMD  
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