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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