Giant P55W, P56W-HK, P56HT, P56W Operating Instructions Manual

Triplex Ceramic
Operating Instructions/
Manual

Models

P55W/P56W/P56W-HK/P56HT

Updated 9/02

Contents:

Installation Instructions: page 2
Pump Specifications: pages 3-5
Exploded View: page 6
Parts List: page 7
Kits: page 8
Trouble Shooting: page 9
Repair Instructions: page 10-13
Pump Mounting Selection
Guide: page 14
Recommended Spare
Parts List: page 14
Torque Specifications: page 14
Dimensions: page 15
Warranty Information: back page

INSTALLATION INSTRUCTIONS

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 installation. 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 160oF (P56W),
190oF (P56W-HK) or 220o F (P56HT), 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 shut­off gun.

4. Use of a dampener is necessary to minimize
pulsation at drive elements, plumbing, connections,
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 pulsation. 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 desig­nated 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 ob­tained from the charts on pages 3-4.

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.

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.

IMPORTANT OPERATING CONDITIONS

Failure to comply with any of these
conditions invalidates the warranty

1. Prior to initial operation, add oil to crankcase so
that the oil level is between the two lines on the oil
dipstick. DO NOT OVERFILL. Giant Recom-
mended Oil. 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.

NOTE: Contact Giant Industries for Service School Information. Phone: [phone].

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.

2

PULLEY

PULLEY

Specifications

Model P55W

Ratings (Continuous)..............................4.9 GPM (18.5 lm) @ 2320 PSI (160 bar) @ 1420 RPM

Ratings (Intermittent) ...............................6.0 GPM (22.7 lm) @ 1000 PSI (69 bar) @ 1750 RPM

Inlet Pressure.......................................................................................... Up to 90 PSI

Plunger Diameter .................................................................................... 18mm

Stroke..................................................................................................... 18.1mm

Crankcase Oil Capacity .......................................................................... 14 fl.oz. (414 ml)

Temperature of Pumped Fluids ............................................................... Up to 160 oF (71 oC)

Inlet Ports............................................................................................... (2) 1/2" BSPP

Discharge Ports ...................................................................................... (2) 3/8" BSPP

Crankshaft Mounting.............................................................................. Either

Shaft Rotation ............................................................................Top of Pulley Towards Fluid End

Weight.................................................................................................... 18 lbs. (8.16 kg)

Crankshaft Diameter............................................................................... 24mm

Volumetric Efficiency @ 1420 RPM....................................................... 0.94

Mechanical Efficiency @ 1420 RPM...................................................... 0.86

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.

P55W PULLEY SELECTION & HORSEPOWER

REQUIREMENTS

PUMP

7.75" 4.00"

7.75" 4.50"

7.75" 5.00"

7.75" 5.50" 1201

7.75" 6.00" 1317

7.75" 6.45" 1420

7.75" 7.75 1750

MOTOR

RPM GPM 500 PSI 1000 PSI 2000 PSI 2320 PSI

851 2.9 1.0 2.0 4.0 4.6
967 3.3 1.1 2.3 4.5 5.2

1084 3.7 1.3 2.5 5.1 5.9

4.1 1.4 2.8 5.6 6.5

4.5 1.5 3.1 6.2 7.2

4.9 1.7 3.4 6.7 7.8

6.0 2.1 4.1

HORSEPOWER INFORMATION

Horsepower ratings shown are the power require­ments for the pump. Gas engine power outputs must
be approximately twice the pump power require­ments 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

1460

=hp

3

PULLEY

PULLEY

Specifications

Models P56W / P56W-HK

Ratings (Continuous)................................6.1 GPM ( 23 lm) @ 1900 PSI (131 bar) @ 1420 RPM

Ratings (Intermittent) ................................6.0 GPM (23 lm) @ 2200 PSI (152 bar) @ 1750 RPM

Ratings (Intermittent) ..................................7.5 GPM (28 lm) @ 1000 PSI (69 bar) @ 1750 RPM

Inlet Pressure.......................................................................................... Up to 90 PSI

Plunger Diameter .................................................................................... 20mm

Stroke..................................................................................................... 18.1mm

Crankcase Oil Capacity .......................................................................... 14 fl.oz. (414 ml)

Temperature of Pumped Fluids ....................................................... Up to 160o F ( 71 o C)(P56W)

................................................................................................ Up to 190o F ( 88 o C)(P56W-HK)

Inlet Ports............................................................................................... (2) 1/2" BSPP

Discharge Ports ...................................................................................... (2) 3/8" BSPP

Crankshaft Mounting.............................................................................. Either

Shaft Rotation ............................................................................Top of Pulley Towards Fluid End

Weight.................................................................................................... 18 lbs. (8.16 kg)

Crankshaft Diameter............................................................................... 24mm

Volumetric Efficiency @ 1420 RPM....................................................... 0.94

Mechanical Efficiency @ 1420 RPM...................................................... 0.86

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.

P56W/P56W-HK PULLEY SELECTION & HORSEPOWER

REQUIREMENTS

PUMP

7.75" 4.00"

7.75" 4.50"

7.75" 5.00"

7.75" 5.50" 1201

7.75" 6.00" 1317

7.75" 6.45" 1420

7.75" 7.75 1750*

MOTOR

RPM GPM 500 PSI 1000 PSI 1500 PSI 1900 PSI 2200* PSI

851 3.7 1.3 2.5 3.8 4.8 5.6
967 4.2 1.4 2.9 4.3 5.5 6.3

1084 4.7 1.6 3.2 4.8 6.1 7.1

5.2 1.8 3.6 5.3 6.8 7.8

5.7 2.0 3.9 5.9 7.4 8.6

6.1 2.1 4.2 6.3 7.9 9.2

7.5 2.6 5.1

HORSEPOWER INFORMATION

Horsepower ratings shown are the power require­ments for the pump. Gas engine power outputs
must be approximately twice the pump power
requirements 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

1460

=hp

*Intermittent Duty Only

4

Specifications

7.75

4.50"

7.75

7.00"

800

900

Models P56HT

750 RPM @ 220o F (104 oC)

Ratings ................................................................................................... 193 GPH (730 lh) (3.2 GPM)

900 RPM @ 195o F (91 oC)

Ratings ................................................................................................... 233 GPH (882 lh) (3.9 GPM)

Discharge Pressure ................................................................................. 900 PSI

Plunger Diameter .................................................................................... 20mm

Stroke..................................................................................................... 18.1 mm

Crankcase Oil Capacity .......................................................................... 14 fl.oz. (414 ml)

Temperature of Pumped Fluids ............................................................... Up to 220o F (104 oc)

Inlet Ports............................................................................................... (2) 1/2” BSPP

Discharge Ports ...................................................................................... (2) 3/8” BSPP

Crankshaft Mounting................................................................. Top of Pulley Towards Fluid End

Weight.................................................................................................... 18 lbs. (8.16 kg)

Crankshaft Diameter............................................................................... 3/4”

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 require­ments for the pump. Gas engine power outputs
must be approximately twice the pump power
requirements 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:

GPH X PSI

87000

= hp =

GPM X PSI

1450

P56HT PULLEY SELECTION AND HORSEPOWER

REQUIREMENTS

PUMP

PULLEY

7.75 3.65"

7.75 5.25"

7.75 7.75"

MOTOR
PULLEY

NPSHR (FT-HEAD)

RPM

GPM RPM 500 PSI 700 PSI 900 PSI

1.7 400 0.6 0.8 1.1

2.2 500 0.8 1.1 1.4

2.6 600 0.9 1.3 1.6

3.5

3.9

1.2 1.7 2.2

1.3 1.9 2.4

5

Exploded View - P55W / P56W / P56W-HK / P56HT

6

P55W / P56W / P56W-HK / P56HT PARTS LIST

ITEM PART DESCRIPTION QTY.

1 07180 Crankcase 1
2 07181 Oil Filler Cap with Gasket 1
2A 07182 Gasket, Oil Filler Cap 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 1
8 07187 Gasket, Oil Sight Glass 1
9 07188 Screw, Crankcase Cover 4
10 07223 Spring Washer (except P56HT) 4
10 07223-0100 Spring Washer, (P56-HT only) 4
11 07190 Oil Drain Plug Assembly 2
11A 13262 Gasket, Oil Drain Plug 2
12 07192 Bearing Cover 2
12 13402 Bearing Cover (P56HT only) 2
13 07193 O-Ring, Bearing Cover 2
14 01166 Radial Shaft Seal 2
15 01086 Ball Bearing 2
16 07196 Screw, Bearing Cover (except P56HT) 6
16 07114 Screw, Bearing Cover (P56HT only) 6
17 07197 Shaft Protector (except P56HT) 1
17 13329 Shaft Protector (P56HT only) 1
18 13330 Crankshaft (24mm) 1
18 13354 Crankshaft (22mm) 1
19 13331 Straight Key, 8mm 1
19 01024 Woodruff Key (P56HT) 1

1

20
21

07199 Connecting Rod Assembly 3

1

01027 Conn. Rod Screw w/ Washer 6
22 07201 Plunger Base w/ S.S. Crosshead 3
23 01031 Crosshead Pin 3
24A 07021 Ceramic Plunger 18mm, P55W 3
24A 06066 Ceramic Plunger, 20mm, P56W (HK) 3
24B 08456 Tension Screw 3
24C 07676 Copper Gasket 3
25 06648 Flinger 3
26 07206 Crankcase Oil Seal 3
26A 07764 Spacer Sleeve 3
28 07207 Shim, Manifold Stud 2

ITEM PART DESCRIPTION QTY.

29 07369 Manifold Head 1
30 07010 Pressure Ring, P55W 3
30 07221 Pressure Ring, P56W 3
31 07011 V-Sleeve, P55W 3
31 06076 V-Sleeve, P56W & P56W-HK 3
31 06537 V-Sleeve, P56HT 3
31A 06537 High Pressure Seal (P56W-HK) 3
31A 13355 High Pressure Seal (P56HT) 3
32 07012 Support Ring, P55W 3
32 07209 Support Ring, P56W, P56W-HK 3
33 07210 Pressure Spring 3
34 07325 Retainer, Spring (except P56HT) 6
34 06018-0100 Retainer, Spring (P56HT only) 6
35 06017-0100 Valve Spring 6
36 06016 Valve Plate 6
37 06014 Valve Seat 6
38 06015 O-Ring, Valve Seat 6
39 07211 Adapter, Inlet Valve (except P56HT) 3
39 13356 Adapter Inlet Valve (P56HT only) 3
40 07212 O-Ring, Adapter 3
41 07213 Plug, Manifold (Inlet Only) 3
42 07214 O-Ring, Manifold Plug (Inlet) 3
43 07034 Plug, and O-ring (Discharge) 3
44 07035 O-Ring, Manifold Plug (Discharge) 3
45 07215 Stud, Manifold 4
46 08040 Hex Nut, Manifold Stud 4
47 08041 Spring Washer, Stud 4
48 07017 Housing, Rear V-Sleeve, P55W 1
48 07036 Housing, Rear V-Sleeve, P56W 1
49 07218 O-Ring, Rear V-Sleeve Housing 1
50 06241 Grooved Seal Ring, Brown, P55W 3
50 08358 Grooved Seal Ring, Black, P56W 3
51 06242 Support Ring, white, P56W 3
51 06240 Support Ring, white, P56W 3
52 07109 Plug, 1/2" BSP 1
52 07110 Gasket, 1/2" (except P56HT) 1
53 13338 Plug, 3/8" BSP 1
53A 08486 Copper Crush Washer, 3/8" BSP

(except P56HT) 1

1

Item #20 comes with item #21.

2

For weep pumps manufactured prior to 7/00
consult earlier manuals (1/98 and before) for the
correct parts in your pumps.

7

P55W / P56W / P56W-HK / P56HT REPAIR KITS

Plunger Packing Kit, P55W, #09088

Item Part # Description Qty.
31 07011 V-Sleeve 3

Plunger Packing Kit, P56W, #09037

Item Part # Description Qty.
31 06076 V-Sleeve 3

Plunger Packing Kit w/ Weep Seals, P55W, #09089

Item Part # Description Qty.
31 07011 V-Sleeve, Front 3
50 06241 Rear V-Sleeve 3
51 06242 Support Ring 3

Plunger Packing Kit w/ Weep Seals, P56W, #09061

Item Part # Description Qty.
31 06076 V-Sleeve, Front 3
50 08358 Rear V-Sleeve 3
51 06240 Support Ring 3

Plunger Packing Kit P56W-HK , #09528

Item Part# Description Qty.
31 06076 V-Sleeve 3
31A 06537 High Temperature Seals 3
50 08358 Rear V-Sleeve 3
51 06240 Support Ring 3

Plunger Packing Kit, P56HT, #09457

Item Part # Description Qty.
31 06537 V-Sleeve 3
31A 13358 High Pressure Seal 3
40 07212 O-Ring Adaptor 3
42 07214 O-Ring Manifold Plug (Inlet) 3
44 07035 O-Ring Manifold Plug (Discharge) 3
49 07218 O-Ring 1
50 08358 Grooved Seal Ring 3
51 06240 Support Ring 3

Ceramic Plunger Kit P55W, #9539

Item Part # Description Qty.
24A 07021 Ceramic Plunger, 18mm 3
24B 08456 Tension Screw 3
24C 07676 Copper Gasket 3
25 06648 Flinger 3

Ceramic Plunger Kit P56W & P56W-HK , #9538

Item Part # Description Qty.
24A 06066 Ceramic Plunger, 20mm 3
24B 08456 Tension Screw 3
24C 07676 Copper Gasket 3
25 06648 Flinger 3

Valve Assembly Kit, P55W/P56W/P56W-HK, #09041

Item Part # Description Qty.
34 07325 Retainer, Valve Spring 3
35 06017-0100 Valve Spring 3
36 06016 Valve Plate 3
37 06014 Valve Seat 3
38 06015 O-Ring, Valve Seat 3
40 07212 O-Ring, Adapter (Inlet Only) 3
42 07214 O-Ring, Inlet Plug 3
44 07035 O-Ring, Discharge Plug 3

Valve Assembly Kit, P56HT, #09458

Item Part # Description Qty.
34 06018-0100 Spring Disc, S.S. 6
35 06017-0100 Valve Spring, S.S. 6
36 06016 Valve Plate 6
37 06014 Valve Seat 6
38 06015 O-Ring 6

8

P55W / P56W / P56W-HK PUMP SYSTEM MALFUNCTIONS

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, Refill 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
Rated, Pressure flow 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

9

P55W / P56W / P56W-HK REPAIR INSTRUCTIONS

NOTE: Always take time to lubricate all metal and nonmetal parts with a light film of oil before reassembly.
This step will ensure proper fit, at the same time protecting the pump nonmetal parts (i.e., the elastomers)
from cutting and scoring.

1. With a 22mm socket, remove
the three discharge (43) and
three inlet (41) manifold plugs.
Check o-ring (44) for wear and
replace as necessary.

4. Drain the oil from the pump.
Turn the pump over to remove
the four manifold stud nuts (46)
with a 17mm wrench.

2. Remove the discharge spring
retainer (34), valve spring (35),
and valve plate (36).

5. Tap the back of the manifold
(29) with a rubber mallet to
dislodge, and slide off the
pump.

3. Use a small slide hammer to
remove valve seats (37) from
manifold (29). Inspect valve
plates (36) and valve seats (37)
for wear. If excessive pitting is
seen, replace the worn parts.
Check valve seat o-ring (38) for
wear and replace as necessary.
Tighten manifold plugs (41 and

43) to 50 ft.-lbs.

6. From the front inlet valve ports,
remove the inlet valve assembly
(34-40) and pressure springs
(33).

7. Turn the manifold (29) over.
Using a 15mm socket, tap out
the v-sleeves, Insert v-sleeve
(31) high temperature seals
( 31A for P56W-HK &P56HT
pumps), support rings (32), and
pressure rings (30) through
back of manifold.

31

30 32 33

8. Inspect and clean the manifold and pressure ring.
Reinstall the pressure ring (30) with the groved side
pointed towards the front. Insert v-sleeve (31) high
temperature seals ( 31A for P56W-HK &P56HT
pumps), support ring (32), and pressure spring (33) into
the manifold (29).

31A

(P56W-HK & P56HT)

10

36 37 35 34

48

50

9. If pitted or worn, replace inlet valve seats (36), valve
plates (37), springs (35) and spring retainers (34).
Re-insert items 34-38 into valve adapter (39). Install
valve assembly (34-40) into manifold (29). Reinstall
manifold plugs (43) and torque plugs to 50 ft.-lbs.

49

10.The rear v-sleeve housing
(48) may be removed by
prying evenly outward
with a flat screwdriver.
After slipping housing
over ceramic plunger
(24A), inspect seals (50)
and o-ring (49) and
replace as necessary. If the
crankcase is to be disas­sembled, the housing
should not be replaced
until later.

24C

11.Inspect ceramic plunger (24A)
tips for wear. If necessary,
replacement of the ceramic
plungers may be accomplished
by removing the plunger bolt
assemblies (24B and 24C) with
a 13mm wrench. Ceramic
plungers should now slide off
the stainless steel plunger base
(22). Excessive resistance to
plunger removal may be
overcome by heating the
stainless steel plunger base.
This will melt any excess loc­tite beneath the ceramic plunger
allowing easy removal.

12.Replace copper ring (24C) onto
plunger bolt (24B). Slide
plunger bolt assembly into
ceramic plunger (24A). Apply
a light film of loc-tite to
plunger bolt threads and place
plunger assembly onto stainless
steel plunger base (22) and
tighten to 105 in.-lbs.

13.To replace plunger oil seals
(26), proceed to “Gear End
Disassembly” section below.
Otherwise, continue as de­scribed below.

11

14.Before replacing pump mani­fold (29), first rotate crankshaft
(18) until two outside plungers
(24A) extend evenly forward.
Next lubricate v-sleeves (50) in
the rear v-sleeve housing (48)
and slide housing over plung­ers. Lubricate ceramic plungers
with a light film of oil. Care­fully and evenly slide manifold
over plungers and press
manifold firmly against
crankcase (1). Replace
manifold stud bolts (45),
washers (47) and nut (46) and
tighten to 35 ft.-lbs.

Gear End Disassembly

NOTE: The manifold (29) weep seal housing (48) and spacer sleeve (26A) must be removed. See above

for directions.

15. Remove the crankcase cover screws (9). Inspect the crankcase cover o-ring (4) for wear. Replace if
necessary.

16. Inspect the dipstick (5) vent hole for signs of clogging. Clean if necessary.

17. To remove the crankshaft (18), first remove the bearing cover plates (12). Remove the key (19).

18. With a 5 mm allen wrench remove the connecting rod screws (21) and rear portion of connecting rod
assemblies (20). Push the connecting rod (20) and plunger rod (22) down as far as possible into the
crankcase housing.

19. Hold the pump rear assembly with a wooden fixture, or other suitable device, in order to secure it while
removing the crankshaft (18). Using a plastic mallet, tap the crankshaft from one side while turning it
from the other side. The turning insures that during this sequence the crankshaft does not become
wedged against the front portion of the connecting rods (20). The far side bearing (15) will remain in the
crankcase (1). When free, the crankshaft can be removed by hand. The opposite side crankshaft seal (14)
will be removed by this procedure. It is important that you turn the crankshaft (18) constantly while

tapping from the opposite end to avoid any binding. The crankshaft bearing (15) remains on the
crankshaft as it is removed. If necessary, use a bearing puller to remove the crankshaft bearing (15).

20. Remove the front portion of the connecting rods (20) and plunger base assembly (22) from the rear of the
pump by pulling straight out of the crankcase crosshead guides. Notice that the connecting rod (20)

halves are numbered or colored. Connecting rods must be positioned with their numbers or colors
on the upper left-hand side, in the same numerical sequence as when they were removed.

21. Using a dowel and a rubber mallet, tap the oil seals (26) out from the rear of crankcase (1). The area onto
which the oil seal rests should be clean and dry. Put a small drop of loc-tite on the oil seals and place into
crankcase with lips facing the rear of the pump.

22. To remove the crosshead pin (23) from the crosshead (22), the assembly should be positioned on a
wooden fixture to avoid damage to crosshead. Drive out the pin on opposite side of mark located on the
crosshead. On those pumps without mark on crosshead, drive out pin by tapping on tapered side of pin.

23. To remove the bearing (15) remaining in the crankcase (1), insert small end of Giant bearing tool and tap
with a rubber mallet until bearing and seal (14) are completely removed. The bearing can only be

removed from the inside by inserting the Giant Bearing Tool through the opposite side of the
crankcase. The crosshead guide in the crankcase should be inspected for possible damage.

24. To reassemble, place the far bearing (15) in the crankcase (1) bearing housing and with the Giant Bearing
tool as a driver, tap into the crankcase using a rubber mallet.

25. Insert the far side crankshaft oil seal (14) with the Giant Bearing Tool making sure it is firmly seated and
well oiled. Always make sure that the crankshaft seal lip does not show signs of wear and that the garter
spring is firmly in place on the seal before reinserting into the pump. Replace the bearing cover (12) and
o-ring (13) and tighten securely.

12

26. Replace the front portion of the connecting rod (20) and plunger rod/ crosshead assembly (22) by press-fitting
the crosshead pin (23). Make sure to insert the beveled edge of the crosshead pin into crosshead. If the
crosshead has a mark, install pin from marked side. The crosshead pin (23) should not extend beyond

either side of the crosshead (22) in order to prevent damage to the crosshead bore of the crankcase (1).

27. Place each crosshead/ plunger assembly into the pump making sure that all of the parts are well oiled before
insertion into the crankcase (1). Notice that the connecting rod (20) halves are numbered or colored.

Connecting rods must be positioned with their numbers or colors on the upper left-hand side, in the
same numerical sequence as when they were removed.

28. Replace near side bearing (15) on crankshaft by using the Giant Bearing Tool and mallet to tap into place.
Take the crankshaft (18) end with the bearing (15) and insert the other end through the bearing housing and
tap with a rubber mallet until the bearing is seated.

29. When reassembling the connecting rods (20), note that the connecting rod halves are numbered or colored
and that the numbers or colors must be matched and aligned. Torque the connecting rod bolts to 125-150 in.­lbs.

30. Insert the near side crankshaft oil seal (14) with the Giant Bearing Tool making sure it is firmly seated and
well oiled. Replace the bearing cover (12) and o-ring (13) and tighten securely.

See instructions above for re-installing fluid end onto the gear end.

31. Fill the P55W / P56W crankcase (1) with 14 oz. of Giant Industries’ oil and check the oil level with the
dipstick (5). Proper level is center of two lines. Reinstall the pump into your system.

13

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 Gallon) p/n 1154 X X
Plunger Packing Kits (1 kit/pump) X

(See page 8 for kit list)

Valve Assembly Kit (1 kit/pump) X

(See page 8 for kit list)
Oil Seal Kit (1 kit/pump) X
(See page 8 for kit list)

Pump Mounting Selection Guide

Bushings

01056 - 22 mm Tapered H Bushing

Pulley & Sheaves
01055 - 9.75” Cast Iron - 2 gr.-AB Section
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”)

P55W / P56W / P56W-HK / P56HT TORQUE SPECIFICATIONS

Position Item# Description Torque Amount

21 01027 Connecting Rod Screw 125-150 in.-lbs.

26D 07202 Bolt Assembly 105 in.-lbs.

41 07213 Plug (Inlet) 50 ft.-lbs.

41A 07034 Plug (Outlet) 50 ft.-lbs.

45 08041 Nut 35 ft.-lbs.

14

P55W / P56W / P56W-HK / P56HT DIMENSIONS - INCHES (mm)

15

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.

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 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)-531­4600 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 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.

GIANT INDUSTRIES, INC., 900 N. Westwood Ave., P.O. Box 3187, Toledo, Ohio 43607
PHONE [phone], FAX [phone], www.giantpumps.com
 Copyright 2002 Giant Industries, Inc.

09/02 P55/56W/P56W-HK/P56HT.PM6