Industrial Triplex Plunger Pumps P57

ModelsP57 & P57-0011Triplex CeramicPlunger PumpOperating Instructions/Repair and ServiceManualContents:Installation Instructions: page 2Pump Specifications: page 3Exploded View: page 4Parts List / Kits: page 5Torque Specifications: page 5Trouble Shooting: page 6Pump Mounting Selection Guide: page 6Recommended Maintenance Schedule: page 6Repair Instructions: page 7Dimensions: back pageWarranty Information: back pageUpdated 7/07INSTALLATION INSTRUCTIONS4. Use of a dampener is necessary to minimizepulsation at drive elements, plumbing, connec-tions, and other system areas. The use of adampener with Giant Industries, Inc. pumps isoptional, although recommended by GiantIndustries, Inc. to further reduce system pulsa-tion. Dampeners can also reduce the severity ofpressure spikes that occur in systems using ashut-off gun. A dampener must be positioneddownstream 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 byfollowing a few guidelines available uponrequest from Giant Industries, Inc. Requiredhorsepower for system operation can be ob-tained from the chart on page 3.6. Before beginning operation of your pumpingsystem, remember: Check that the crankcaseand seal areas have been properly lubricated perrecommended schedules. Do not run the pumpdry for extended periods of time. Cavitation willresult in severe damage. Always remember tocheck that all plumbing valves are open and thatpumped media can flow freely to the inlet of thepump.IMPORTANT OPERATING CONDITIONSFailure to comply with any of these conditions invalidates the warranty.2. Pump operation must not exceed ratedpressure, volume, or RPM. A pressure reliefdevice must be installed in the discharge of thesystem.3. Acids, alkalines, or abrasive fluids cannot bepumped unless approval in writing is obtainedbefore operation from Giant Industries, Inc.4. Run the pump dry approximately 10 secondsto drain the water before exposure to freezingtemperatures.1. Prior to initial operation, add oil to thecrankcase so that oil level is between the twolines on the oil dipstick. DO NOT OVERFILL.Use Giant 20W-50 oil (p/n 01153) or useSAE 80-90W Industrial Gear Lube oil(p/n 01154),Crankcase oil should be changed after thefirst 50 hours of operation, then at regularintervals of 500 hours or less depending onoperating conditions.Installation of the Giant Industries, Inc.,pump is not a complicated procedure, butthere are some basic steps common to allpumps. The following information is to beconsidered as a general outline for installa-tion. If you have unique requirements, pleasecontact Giant Industries, Inc. or your localdistributor for assistance.1. The pump should be installed flat on a base toa maximum of a 15 degree angle of inclinationto ensure optimum lubrication.2. The inlet to the pump should be sized for theflow rate of the pump with no unnecessaryrestrictions that can cause cavitation. Teflontape should be used to seal all joints. If pumpsare to be operated at temperatures in excess of1600 F, it is important to insure a positive headto the pump to prevent cavitation.3. The discharge plumbing from the pumpshould be properly sized to the flow rate toprevent line pressure loss to the work area. It isessential to provide a safety bypass valvebetween the pump and the work area to protectthe pump from pressure spikes in the event of ablockage or the use of a shut-off gun.Finally, remember that high pressure operation in a pump system has many advantages. But, if it is used carelesslyand without regard to its potential hazard, it can cause serious injury.2U.S. ..................................... MetricFlow .............................................................. 1.3 GPM ............................. 5.1 Liters/min.Discharge Pressure (Continuous) ................. 5000 PSI ............................. 350 BarDischarge Pressure (Intermittent) ................. 6525 PSI ............................. 450 BarMax. Inlet Pressure ....................................... 145 PSI ............................... 10 BarMax. Crankshaft Speed .............................................................................. 1420 RPMPlunger Diameter .......................................... 0.47” ................................... 12 mmStroke ............................................................ 0.56” ................................... 18.1 mmCrankcase Oil Capacity ................................ 15.2 fl.oz. ............................ 0.45 LitersMax. Temperature of Pumped Fluids ........... 160 oF .................................. 70 oCInlet Ports ................................................................................................... (2) 1/2" BSPDischarge Ports ........................................................................................... (2) 3/8" BSPCrankshaft Mounting .................................................................................. EitherShaft Rotation ............................................... Top of Pulley Towards Fluid EndWeight ........................................................... 17.2 lbs. .............................. 7.8 Kg.Crankshaft Diameter ..................................... 0.87” ................................... 22mmConsult the factory for special requirements that must be met if the pump is tooperate beyond one or more of the limits specified above.SpecificationsModels P57 & P57-0011PULLEY INFORMATIONPulley selection and pump speed are based on a 1725RPM motor and "B" section belts. When selectingdesired GPM, allow for a ±5% tolerance on pumpsoutput due to variations in pulleys, belts and motorsamong manufacturers.1. Select GPM required, then select appropriatemotor and pump pulley from the same line.2. The desired pressure is achieved by selecting thecorrect nozzle size that corresponds with the pumpGPM.HORSEPOWER INFORMATIONHorsepower ratings shown are the power require-ments for the pump. Gas engine power outputs mustbe approximately twice the pump power require-ments shown above.We recommend that a 1.1 service factor be specifiedwhen selecting an electric motor as the power source.To compute specific pump horsepower requirements,use the following formula:GPM X PSI =hp14603P57 PULLEY SELECTION & HORSEPOWER REQUIREMENTSPUMP PULLEY RPM GPM 3000 PSI 4000 PSI 5000 PSI 6525 PSI*7.75" 500 0.5 1.0 1.4 1.7 2.37.75" 750 0.7 1.4 1.9 2.4 3.27.75" 1000 0.9 1.9 2.5 3.1 4.17.75" 1250 1.1 2.3 3.0 3.8 5.07.75" 1420 1.3 2.7 3.6 4.5 5.9Exploded View - P57 & P57-00114P57 & P57-0011 SPARE PARTS LISTITEM PART DESCRIPTION QTY.29 12226 Manifold 130 12130 Pressure Ring 331 08354 Grooved Seal (P57) 331 07391-0010 Grooved Seal, Viton (P57-0011) 332 07941 Support Ring 333 12132 Pressure Spring 333A 12133 Support Disc I 333B 12134 Support Disc II 334 07907 Spring Tension Disc 635 07906-0100 Valve Spring 636 07491 Valve Plate 637 07849 Valve Seat 638 07853 O-Ring (P57) 638 07853-0001 O-Ring, Viton (P57-0011) 639 07940 Suction Valve Retainer 340 07212 O-Ring (P57) 340 07212-0001 O-Ring, Viton (P57-0011) 341 12135 Plug, Inlet 342 07214 O-Ring (P57) 342 07214-0001 O-Ring, Viton (P57-0011) 343 12136 Plug, Outlet 344 07913 O-Ring (P57) 344 07913-0001 O-Ring, Viton (P57-0001) 345 07215 Stud Bolt 446 08040 Hex Nut 447 08041 Spring Ring 452 12250 Plug, 1/2” BSP, S.S. 153 12138 Plug, 3/8” BSP, S.S. 1ITEM PART DESCRIPTION QTY.1 07180 Crankcase 12 07181 Oil Fill Plug Assembly 12A 07182 Gasket 13 07183 Cover, Crankcase 14 07184 O-Ring, Crankcase Cover 15 07185 Oil Dip Stick Assembly 16 01009 O-Ring, Dip Stick 17 07186 Oil Sight Glass Assembly 19 07188 Screw, Crankcase Cover 410 07223-0100 Spring Washer 411 07190 Oil Drain Plug Assembly 111A 07191 Gasket 112 13402 Bearing Cover 213 07193 O-Ring, Bearing Cover 214 01166 Radial Shaft Seal 215 01086 Bearing 216 07114 Hex Screw with Washer 617 05023 Shaft Protector 118 12128 Crankshaft 119 01024 Woodruff Key 120 07199 Connecting Rod 321 01027 Screw with Washer 622 07396 Plunger Assy. 323 01031 Crosshead Pin 325 13403 Flinger 326 08026 Radial Shaft Seal 326A 13346 Spacer Sleeve 328 07207 Centering Sleeve 2P57 & P57-0011 REPAIR KITSValve Assembly Kit #09315 (P57)Item Part # Description Qty.34 07907 Spring Tension Disc 635 07906-0010 Valve Spring 636 07491 Valve Plate 637 07849 Valve Seat 638 07853 O-Ring 640 07212 O-Ring 342 07214 O-Ring 344 07913 O-Ring 3Oil Seal Kit #09314 (P57 & P57-0011)Item Part # Description Qty.25 13403 Flinger 326 08026 Radial Shaft Seal 3Plunger Packing Kit #09313 (P57)Item Part # Description Qty.31 08354 Grooved Seal 332 07941 Support Ring 340 07212 O-Ring 342 07214 O-Ring 3Plunger Packing Kit #09313-0011 (P57-0011)Item Part # Description Qty.31 07391-0010 Grooved Seal Assy. 332 07941 Support Ring 340 07212-0001 O-Ring, Viton 342 07214-0001 O-Ring, Viton 35Position Item# Description Torque Amount21 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 SPECIFICATIONSPUMP SYSTEM MALFUNCTIONPUMP SYSTEM MALFUNCTIONSMALFUNCTION CAUSE REMEDYThe Pressure and/ or the Delivery DropsWorn packing seals Replace packing sealsBroken valve springs Replace springsBelt slippage Tighten or Replace beltWorn or Damaged nozzle Replace nozzleFouled discharge valve Clean valve assemblyWorn or Plugged relief valve on pump Clean, Reset, and Replace worn partsCavitations Check suction lines on inletof pump for restrictionsUnloader Check for proper operationWater in Crankcase High Humidity Reduce oil change intervalsWorn Seals Replace sealsNoisy Operating Worn bearings Replace bearings, Refill crankcase oil with recommendedlubricantCavitation Check inlet lines for restrictions and/or proper sizingRough/Pulsating Operation with Pressure DropWorn packing Replace packingInlet restriction Check system for stoppageair leaks, correctly sized inlet plumbing to pumpAccumulator pressure Recharge/Replace accumulatorUnloader Check for proper operationCavitation Check inlet lines for restrictionsand/or proper sizePump Pressure as Drop at gun Rated, PressureRestricted discharge plumbing Re-size discharge plumbing to flow rate of pump Excessive LeakageWorn plungers Replace plungersWorn packing/seals Adjust or Replace packing sealsExcessive vacuum Reduce suction vacuumCracked plungers Replace plungersInlet pressure too high Reduce inlet pressureHigh Crankcase TemperatureWrong Grade of Oil Giant oil is recommendedImproper amount of oil in crankcase Adjust oil level to proper amount6Pump Mounting Selection GuideBushings01056 - 22 mm Tapered H BushingPulley & Sheaves01061 - 7.75” Cast Iron 1 gr. - ABSection01062 - 7.75” Cast Iron - 2 gr. - ABSectionRails01034 -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 ListCheck Daily Weekly 50hrs Every Every Every500 hrs 1500 hrs 3000 hrsOil Level/Quality XOil Leaks XWater Leaks XBelts, Pulley XPlumbing XRecommended Spare PartsOil Change (1 Quart) p/n 01153 X XSeal 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 & P57-0011CAUTIONThe stainless steel valve plugs (41 and 43) can seize (when being removed from the manifold). To release tensionbeforehand, 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 ValvesInlet Valves1. Using a socket wrench, carefully remove valve plugs (41 and 43). Take out the suction valve adaptor (39) along with thesuction 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 Valves5. 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 Pipe1. Carefully remove the valve plugs (41). Remove stud nuts (46) and washer (47) from the manifold (29). By pulling it outtowards 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 changeddue 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 Crankcase1. 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. Connectingrods 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 inthe 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 shaftseals (26). Rough surfaces indicate a problem with lubrication and/or possible rough running of the pump. If yoususpect that the pump has been running under cavitation or heavy pulsations, make improvements on the inlet and/ordischarge 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 asocket wrench. With the seal lip facing forward, replace them into the crankcase (1).To Reassemble1. Replace the front halves of the connecting rod (22) and plunger assembly (22). Make sure that they are in the sameposition 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 ontothe 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 (15NM).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)-531-46007P57 & P57-0011 PUMP DIMENSIONS (MM)GIANT INDUSTRIES, INC., 900 N. Westwood Ave., P.O. Box 3187, Toledo, Ohio 43607PHONE (419) 531-4600, FAX (419) 531-6836, www.giantpumps.com? Copyright 2007 Giant Industries, Inc.07/07 P57.PMDGIANT INDUSTRIES LIMITED WARRANTYGiant Industries, Inc. pumps and accessories are warranted by the manufacturer to be free fromdefects in workmanship and material as follows:1. For portable pressure washers and car wash applications, the discharge manifoldswill never fail, period. If they ever fail, we will replace them free of charge. Our otherpump parts, used in portable pressure washers and in car wash applications, arewarranted 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 consumerpumps.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.This warranty is limited to repair or replacement of pumps and accessories of which the manufacturer’sevaluation shows were defective at the time of shipment by the manufacturer. The following itemsare 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 forthin 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 thoseproducts returned freight prepaid to Giant Industries which are deemed to be defective due toworkmanship or failure of material. A Returned Goods Authorization (R.G.A.) number and completedwarranty evaluation form is required prior to the return to Giant Industries of all products underwarranty 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 providedhereunder and the MANUFACTURER SHALL NOT BE LIABLE FOR FURTHER LOSS, DAMAGES,OR EXPENSES, INCLUDING INCIDENTAL AND CONSEQUENTIAL DAMAGES DIRECTLY ORINDIRECTLY ARISING FROM THE SALE OR USE OF THIS PRODUCT.THE LIMITED WARRANTY SET FORTH HEREIN IS IN LIEU OF ALL OTHER WARRANTIES ORREPRESENTATION, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION ANY WAR-RANTIES OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE AND ALL SUCHWARRANTIES ARE HEREBY DISCLAIMED AND EXCLUDED BY THE MANUFACTURER.