Giant CP218 User's Manual
Contents
1. Carefully slide the valve casing 26 out over the plungers If the crankcase oil seals 19 are to be replaced they can be removed by prying loose with a flat screwdriver Take care not to make contact with the plunger REPAIR INSTRUCTIONS CP200 10 If the ceramic plunger pipe NOTE If there are 16B is damaged remove deposits of any kind i e the plunger bolt 16C and lime deposits in the plunger extension 16E valve casing be certain CP230 only Discard the that the weep holes in the old plunger pipe 16B weep return ring 25 and copper gasket 16D and valve casing 26 Clean the old locktite from have not been plugged the plunger bolt 16C and plunger base 16A Replace the plunger pipe plunger extension 16E P230 only and locktite the plunger bolt and torque to 220 inch pounds Make sure you use a new gasket 16D with the plunger bolt Reassembly sequence of the CP200 pumps 1 If oil seals 19 were removed replace with seal lip towards crankcase Lubricate seals before replacing 2 Replace seal case 20 with o rings 21 over plungers Generously lubricate o rings and oil seal before reassembly Replace v sleeve 23A over plungers 16 3 Generously lubricate v sleeve 23 Assemble v sleeves 22 into valve casing 26 Make sure spacer ring 30E CP230 pumps only is present in the valve casing Assemble weep return ring 25 and pressure ring 24 over plungers 16 Slide valve c2. 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 With a 22mm socket wrench remove the 3 discharge valve plugs and 3 inlet valve plugs 32 Inspect the o ring 33 for wear and replace if damaged Remove the o ring 31 Inspect all parts for wear and replace as necessary For pumps manufactured prior to 5 97 tighten plugs 32 to 33 ft lbs otherwise apply one drop of Loctite 243 to the valve plugs 32 and tighten to 59 ft Ibs Remove the weep return ring 25 pressure ring 24 and v sleeve 23 from the valve casing 26 The spacer ring 30A on CP230 pumps may remain inside the valve casing Using a needle nose pliers remove the inlet and discharge valve assemblies 27 31 Next use a 5mm allen wrench to remove the 8 socket head cap screws 34 Remove the v sleeve 23A from the seal case 20 Inspect all parts including o ring 21 for wear and replace as necessary Check surfaces of plunger 16 A damaged surface will cause accelerated wear on the seals Depos its of any kind must be carefully removed from the plunger surface A damaged plunger must be replaced By inserting a small screw driver between the valve seat 27 and the valve spring retainer 30 the valve assembly can be separated
3. DESCRIPTION Tension Screw Copper Gasket 3 Copper Gasket CP230 only 3 Plunger Extension CP230 only 3 Wrist Pin O Ring OilSeal Seal Case O Ring V Sleeve Weep V Sleeve Teflon Pressure Ring Weep Return Ring Valve Casing Valve Seat Valve Plate Valve Spring Valve Spring Retainer Spacer Ring CP230 only O Ring Valve Plug Valve Assembly O Ring Hex Head Cap Screw Plug 3 8 BSP 3 3 Repair Kits CP200 Series Plunger Packing Kit Oil Seal Kit Part 09554 Item Part 23 08087 Part 09144 Description A Item Part Description V Sleeve weep 19 08356 0010 OilSeal 23A 08087 0020 V Sleeve brown 24 07904 Pressure Ring Valve Assembly Kit Part 09556 Item Part Description 07849 06809 06816 07907 06817 Valve Seat Valve Plate Valve Spring Valve Spring Retainer O Ring Pump Torque Specifications CP200 Series Position Description Torque Amount 16C Tension Screw Plunger 220 in Ibs 32 Valve Plug 59 ft lbs Hex Head Cap Screw Valve Casing 105 in Ibs Pump Mounting Selection Guide Bushings 01074 24 mm Tapered H Bushing Pulley amp Sheaves 01061 7 75 Cast Iron 1 gr AB Section 01062 7 75 Cast Iron 2 gr AB Section Rails 01160 Plated Steel Channel Rails L 5 75 x W 1 00 x h 2 50 01161 Plated Steel Channel Rails L 5 75 x W 1 00 x H 2 50 Qty 3 1 REPAIR INSTRUCTIONS CP200 PUMPS NOTE
4. 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 FURTHERLOSS 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 ORIMPLIED INCLUDING WITHOUT LIMITATION ANY WARRAN TIES 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 419 531 4600 FAX 419 531 6836 www giantpumps com Copyright 2002 Giant Industries Inc 4102 CP200 PM6
5. as well so that the weep holes are down at the six o clock position Exchange the oil fill and the oil drain plugs also Refer to the repair instructions as necessary for the proper assembly sequence HORSEPOWER RATINGS The rating shown are the power requirements for the pump Gas CP220 HORSEPOWER REQUIREMENTS engine power outputs must be approximately twice the pump power requirements shown above We recommend a 1 15 service factor be specified when selecting an electric motor as the power source 750 To compute specific pump horse power requirements use the following formula HP GPM X PSD 1450 Specifications Model CP230 Ratings Inlet Pressure Temperature of Pumped Fluids Inlet Ports Discharge Ports 0 5 GPM 2030 PSI 14 to 140 PSI 2 3 8 BSP 2 3 8 BSP Shaft Rotation Crankshaft Diameter Key Width Shaft Mounting Right Side Facing Manifold 11 Ibs 11oz Positive inlet pressure required 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 NOTE In order to drive the pump from the side opposite the present shaft extension simply remove the valve casing from the crankcase and rotate the pumps 180 degrees to the desired position Be certain to rotate the seal case item 20 as well so that the weep holes are down at the six o clock position Exchange the oil fill and the oil drain plugs also Refer
6. to the repair instructions as necessary for the proper assembly sequence HORSEPOWER RATINGS The rating shown are the power requirements for the pump Gas engine power outputs must be approximately twice the pump power requirements shown above CP230 HORSEPOWER REQUIREMENTS RPM GPM _ 500 PSI 1000 PSI 1500 PS 2030 PSI We recommend a 1 15 service factor be specified when selecting an electric motor as the power source To compute specific pump horse power requirements use the following formula 750 HP GPM X PSD 1450 Exploded View CP200 Series PARTNO 08300 06773 08302 08302 L 07190 08005 06273 08192 07188 07223 0100 08303 08490 08492 07225 01166 08020 01020 08440 DESCRIPTION Crankcase Oil Dipstick with O Ring Crankcase Cover Short Crancase Cover Long Drain Plug amp Gasket O Ring Oil Drain Plug Gasket Screw Crankcase Cover Spring Washer Bearing Cover I Oil Sight Glass O Ring Screw with Lock Washer Radial Shaft Seal Ball Bearing Ball Bearing Crankshaft CP218 Crankshaft CP 220 Crankshaft CP 230 Woodruff Key Connecting Rod Plunger Complete 18mm Plunger Base Plunger Pipe Spare Parts CP200 Series QTY 1 16C 16D 16D 16E 17 18 19 20 21 23 TEM PARTNO 08456 07676 07204 0100 06823 08442 07770 08356 0010 08444 06815 08087 08087 0020 07904 08445 08446
7. Series Triplex Ceramic Plunger Pump Operating Instructions Repair and Service Manual For Models CP218 CP220 CP230 Contents Installation Instructions page 2 Pump Specifications pages 3 5 Exploded View page 6 Parts List page 7 Recommended Spare Kits amp Torque Specifications page 8 Pump Mounting Selection Guide page 8 Repairlnstructions pages 9 10 Trouble Shooting page 1 1 Preventative Maintenance page 1 1 Dimensions back page 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 installa tion 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 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 t
8. ard 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 crank case so that oil level is between the two lines on the oil dipstick DO NOT OVERFILL Use Giant Oil or Use SAE 0 W 40 when pumping CO under 32 F 0 C 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 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 Specifications Model CP218 Ratings 1 4 GPM 2030 PSI Inlet Pressure 14 to 140 PSI Temperature of Pumped Fluids Inlet Ports Discharge Ports Shaft Rotation Right Side Facing Manifold 11 Ibs 110z Crankcase Oil Capacity Extended Crankcase Oil Capacity Positive inlet pressure required 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 NOTE In order to drive the pump from the side opposite the present shaft extension
9. asing over plungers and seat firmly Replace the eight socket head cap screws 34 and tighten to 105 inch pounds in a crossing pattern Replace the six o rings 31 and the six valve assemblies 32X Now replace the six valve plug o rings 33 Apply one drop of Loctite 243 to the valve plugs 32 and tighten to 59 ft Ibs NOTE Contact Giant Industries for Service School Information Phone 419 531 4600 10 MALFUNCTION The Pressure and or the Delivery Drops Water in crankcase Noisy Operation Rough Pulsating Operation with Pressure Drop Pump Pressure as gun Pressure Excessive Leakage High Crankcase Temperature PUMP SYSTEM MALFUNCTION CAUSE Worn packing seals Broken valve spring Belt slippage Worn or Damaged nozzle Fouled discharge valve Fouled inlet strainer Worn or Damaged hose Worn or Plugged relief valve on pump Cavitation pump for restrictions Unloader High humidity Worn seals Worn bearings oil with Cavitation Worn packing Inlet restriction Accumulator pressure Unloader Cavitation Restricted discharge plumbing Worn plungers Worn packing seals Excessive vacuum Cracked plungers Inlet pressure too high Wrong Grade of oil Improper amount of oil in crankcase REMEDY Replace packing seals Replace spring Tighten or Replace belt Replace nozzle Clean valve assembly Clean strainer Repair Replace hose Clean Reset and Replace worn parts Check suction lines
10. o 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 connec tions 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 pulsa tion 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 desig nated 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 6 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 ifit is used carelessly and without reg
11. on inlet of Check for proper operation Reduce oil change interval Replace seals Replace bearings Refill crankcase recommended lubricant Check inlet lines for restrictions and or proper sizing Replace packing Check system for stoppage air leaks correctly sized inlet plumbing to pump Recharge Replace accumulator Check for proper operation Check inlet lines for restrictions and or proper size Re size discharge plumbing to Drop at flow rate of pump Rated Replace plungers Adjust or Replace packing seals Reduce suction vacuum Replace plungers Reduce inlet pressure Giant oil is recommended Adjust oil level to proper amount Preventative Maintenance Check List amp Recommended Spare Parts List Oil Level Quality Daily Weekly 50hrs Every 1500 hrs Every 3000 hrs Oil Leaks Water Leaks Belts Pulley X Plumbing X Recommended Spar Oil Change 1 Quart p n 1153 X Seal Spare Parts 1 kit pump See page 8 for kit list Oil Seal Kit 1 kit pump See page 8 for kit lit Valve Spare Parts 1 kit pump See page 8 for kit list 11 CP200 SERIES DIMENSIONS inches 15 n Perey ana gel 1 2 Discharge l TAr 3I8 BSP Tii rder B Emm If de Key CIN 5488 T fei ng ire 21 PATTIE Tw n K niet 2x 3 8 BSP 26 57 E ee ee GIANT INDUSTRIES LIMITED WARRANTY Giant Indu
12. simply remove the valve casing from the crankcase and rotate the pumps 180 degrees to the desired position Be certain to rotate the seal case item 20 as well so that the weep holes are down at the six o clock position Exchange the oil fill and the oil drain plugs also Refer to the repair instructions as necessary for the proper assembly sequence HORSEPOWER RATINGS The rating shown are the power CP218 HORSEPOWER REQUIREMENTS requirements for the pump Gas RPM GPM 500 PSI 1000 PSI 1500 PSI 2030 PSI engime power ouspule must be approximately twice the pump power requirements shown above We recommend a 1 15 service factor be specified when selecting an electric motor as the power source To compute specific pump horse power requirements use the following formula HP GPM X PSD 1450 Specifications Model CP220 Ratings 1 9 GPM 2030 PSI Inlet Pressure 14 to 140 PSI Plunger Diameter Stroke Inlet Ports Discharge Ports Shaft Rotation Right Side Facing Manifold 11 Ibs 11oz Crankcase Oil Capacity Extended Crankcase Oil Capacity 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 NOTE In order to drive the pump from the side opposite the present shaft extension simply remove the valve casing from the crankcase and rotate the pumps 180 degrees to the desired position Be certain to rotate the seal case item 20
13. stries 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 self serve 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 applica tions 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 Normal wear and tear to standard wear parts Use of repair parts other than those manufactured or authorized by Giant Improper use of the product as a component part Changes or modifications made by the customer or third party 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
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