How it Works
Giant
Loading...
P57
User Manual
8 pgs137.62 Kb0

Giant P57, P57-0011 User Manual

Download
Page 1
Models P57 & P57-0011
Triplex Ceramic Plunger Pump Operating Instructions/ Repair and Service Manual
Updated 7/07
Contents:
Page 2
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
0
160
F, 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.
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 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.
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 the crankcase so that oil level is between the two lines on the oil dipstick. DO NOT OVERFILL.
2. Pump operation must not exceed rated pressure, volume, or RPM.
A pressure relief device must be installed in the discharge of the system.
Use Giant 20W-50 oil (p/n 01153) or use SAE 80-90W Industrial Gear Lube oil (p/n 01154),
3. Acids, alkalines, or abrasive fluids cannot be pumped unless approval in writing is obtained before operation from Giant Industries, Inc.
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.
4. Run the pump dry approximately 10 seconds to drain the water before exposure to freezing temperatures.
2
Page 3
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.
P57 PULLEY SELECTION & HORSEPOWER REQUIREMENTS
PUMP
PULLEY
7.75"
7.75"
7.75"
7.75"
7.75"
RPM GPM 3000 PSI 4000 PSI 5000 PSI 6525 PSI*
500 0.5 1.0 1.4 1.7 2.3
750 0.7 1.4 1.9 2.4 3.2 1000 0.9 1.9 2.5 3.1 4.1 1250 1.1 2.3 3.0 3.8 5.0 1420 1.3 2.7 3.6 4.5 5.9
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
Page 4
Exploded View - P57 & P57-0011
4
Page 5
P57 & P57-0011 SPARE PARTS LIST
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
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
P57 & P57-0011 REPAIR KITS
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 Seal Assy . 3 32 07941 Support Ring 3 40 07212-0001 O-Ring, Viton 3 42 07214-0001 O-Ring, Viton 3
P57 & P57-0011 TORQUE SPECIFICATIONS
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)
Valve Assembly Kit #09315 (P57)
Item Part # Description Qty. 34 07907 Spring T ension 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
5
Page 6
PUMP SYSTEM MALFUNCTION
Y
y
g
y
y
g
p
g
Adj
p
PUMP SYSTEM MA LFUNCTIONS
MALFUNCTION CAUSE REMED
The P re s su re a n d / or the Deliver
Water in Crankcase Hi
Worn packing seals Replace packing seals
Drops
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
Cavitations C heck suction lines on inlet
Unloader Check for proper operation
h Humidit
Worn Seals Replace seals
wo rn pa rts
of pump fo r res trictio ns
Reduce oil change intervals
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
Operatin
Nois crankcase oil with recommended
and/or proper sizing
Ro u g h /P u lsa tin g Op e ra tio n with Pressure Dro
Pu m p P re s su re a s Drop at gun Rated, Pressure
Ex ce s siv e
e
Leaka
Hig h C ra n kc a se Tem
erature
Wo rn bearings Replace bearings, R e fill
Ca v ita tio n Ch e c k in le t lin es for re s trictio n s
Worn packing Replace packing
Inlet restriction Check sy stem for stoppage
Accumu lator pressure Recharge/Replace accumulator
Unloader Check for proper operation Ca v ita tio n Ch e c k in le t lin es for re s trictio n s
Restricted discharge plumbing Re-size discharge plumbing to flow
Worn plungers Replace plungers
Worn packing/seals
Excessive vacuum Reduce suction vacuum Cracked plungers Replace plungers Inlet p re ss u re too h ig h Re d u ce in le t pre s su re
Wrong Grade of Oil Giant oil is recommended
Improper amount of oil in crankcase Adjust oil level to proper amount
lubricant
air leaks, correctly sized inlet p lu m b in g to p u m p
and/or proper size
rate of pump
ust or Replace packing seals
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 W ater 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)
6
Page 7
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
Page 8
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.
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 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 WAR­RANTIES OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE AND ALL SUCH WARRANTIES ARE HEREBY DISCLAIMED AND EXCLUDED BY THE MANUFACTURER.
prior to the return to Giant Industries of all products under
GIANT INDUSTRIES, INC., 900 N. Westwood Ave., P.O. Box 3187, Toledo, Ohio 43607 PHONE (419) 531-4600, FAX (419) 531-6836, www.giantpumps.com Copyright 2007 Giant Industries, Inc.
07/07 P57.PMD
Loading...
Buy Points How it Works FAQ Contact Us Questions and Suggestions Privacy Policy Cookie Policy Terms of Use