Giant P200A User's Manual
Contents
1. e Fa Fa CO Oh Fa Fa For pumps w 3 8 Inlet order p n 08446 Specifications Model P223A p to 3 0 GPM Discharge Pressure Continuous Jp to 2000 PSI Discharge Pressure Intermittent Jp to 2320 PSI Inlet Pressure 4 to 140 PSI Jp to 3450 RPM 3mm Temperature of Pumped Fluids Jp to 160 F Inlet Ports 2 1 2 BSP Discharge Ports 2 3 8 BSP Shaft Rotation Top of Pulley Towards Fluid End Crankshaft Diameter Key Width Shaft Mounting Right Side Facing Manifold 11 Ibs 1102 Crankcase Oil Capacity Extended Crankcase Oil Capacity Volumetric Efficiency 1750 RPM Mechanical Efficiency 1750 RPM 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 crank case 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 P223A HORSEPOWER The rating shown are the power REQUIREMENTS requirements for the pump Gas engine power outputs must be approximately twice the pump power requirements shown above We recomm2. 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 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 For maintenance of the gear end of your pump contact Giant Industries or your local distributor Phone 419 531 4600 NOTE Contact Giant Industries for Service School Information Phone 419 531 4600 14 P200A DIMENSIONS inches 8mm Wide Key DIN 6888 Discharge 3 8 BSP 7 9 Short 9 2 Long 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 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 One 1 year from the date of shipment for all other Giant industrial and consumer pumps Six 6 months from the date of shipment for all rebuilt pumps Ninety 90 days from the date of shipment for all Giant a
3. 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 crank case 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 P217A HORSEPOWER REQUIREMENTS requirements for the pump Gas engine power outputs must be approximately twice the pump 17 12 18 23 27 Pope EE 3450 We recommend a 1 15 service factor be specified when selecting an electric motor as the power source To compute specific pump horse SPECIAL NOTE power requirements use the The theoretical gallons per revolution following formula gal rev is 0 0009855 To find specific outputs at various RPM use the formula GPM 0 0009855xRPM Intermittent duty only HP GPM X PSD 1450 Specifications Model P218A p to 3 4 GPM Discharge Pressure Continuous Jp to 2000 PSI Discharge Pressure Intermittent Jp to 2320 PSI Inlet Pressure 4 35 to 140 PSI Jp to 1750 RPM Temperature of Pumped Fluids Inlet Ports Discharge Ports Shaft Rotation Crankshaft Diameter Key Width Shaft Mounting Right Side F
4. R 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 2001 Giant Industries Inc 03 01 P200A PM6
5. Series P200A THE EAGLE LINE Updated 3 01 Triplex Ceramic Plunger Pump Operating Instructions Repair and Service Manual For Models P217 Contents Installation Instructions page 2 Pump Specifications pages 3 7 10 Exploded View page 8 Parts List page 9 Kits amp Torque Specifications page 11 Trouble Shooting page 12 RepairInstructions pages 13 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 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 to provide a safety bypass valve between the pump and the work a
6. acing Manifold 11 Ibs 1102 Crankcase Oil Capacity Extended Crankcase Oil Capacity Volumetric Efficiency 1750 RPM Mechanical Efficiency 1750 RPM 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 crank case 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 P218A HORSEPOWER REQUIREMENTS Ee Tune sown ate the power requirements for the pump Gas 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 To compute specific pump horse SPECIAL NOTE power requirements use the The theoretical gallons per revolution following formula gal rev is 0 00193 To find specific outputs at various RPM use the formula GPM 0 00193 x RPM Intermittent duty only HP GPM X PSD 1450 Specifications Model P219A Jp to 4 2 GPM Discharge Pressure Continuous Jp to 2000 PSI Discharge Pressure Intermittent J
7. ase Noisy Operation Rough Pulsating Operation with Pressure Drop Pressure Drop at Gun Excessive Leakage High Crankcase Temperature PUMP SYSTEM MALFUNCTION CAUSE Worn packing seals Broken valve spring Belt shppage Worn or Damaged nozzle Fouled discharge valve Fouledinlet strainer Worn or Damaged hose Worn or Pluggedreliefvalve on pump Cavitation Unloader Highhumidity Wornseals Worn bearings Cavitation Wompacking Inletrestriction Accumulator pressure Unloader Cavitation Restricted discharge plumbing Worm 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 andReplacewom parts Check suction lines on inlet of pump forrestrictions Check for proper operation Reduce oil change interval Replace seals Replace bearings Refill crankcase oilwithrecommendedlubricant Checkinletlines forrestrictions and or proper sizing Replace packing Check system for stoppage air leaks correctly sizedinlet plumbing topump Recharge Replace accumulator Check for proper operation Check inlet lines forrestrictions and or proper size Re size discharge plumbing to flowrate of pump Replace plungers Adjust or Replace packing seals Reduce su
8. at 27 and the valve spring retainer 30 the valve assembly can be separated 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 P200A SERIES If the ceramic plunger pipe 16B is damaged remove the plunger bolt 16C Discard the old plunger pipe 16B and copper gasket 16D and clean the old locktite from the plunger bolt 16C and plunger base 164 Replace the plunger with the new one and locktite the plunger bolt and torque to 220 inch pounds NOTE If there are deposits of any kind Ge lime deposits in the valve casing be certain that the weep holes in the weep return ring 25 and valve casing 26 have not been plugged Reassembly sequence of the P200A series pump 1 2 3 If oil seals 19 were removed replace with seal lip towards crankcase Lubricate seals before replacing Replace seal case 20 with o rings 21 over plungers Generously lubricate o rings and oil seal before reassembly Replace v sleeve 23 over plungers 16 Generously lubricate v sleeve 23 Assemble v sleeves 22 into valve casing 26 Assemble weep return ring 25 and pressure ring 24 over plungers 16 Slide valve casing over plungers and seat firmly Replace the eight socket head cap screws 34 and tighten to
9. ccessories 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 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 O
10. ction vacuum Replace plungers Reduceinlet pressure Giant oil is recommended Adjust oil level to proper amount 7 REPAIR INSTRUCTIONS P200A SERIES NOTE Always take time to Inbricate 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 Remove the v sleeve 23 from the seal case 20 Using a needle nose pliers remove the inlet and discharge valve assemblies Next use a 5mm allen wrench to remove the 8 socket head cap screws 34 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 se
11. end a 1 15 service factor be specified when selecting an electric motor as the power source To compute specific pump horse SPECIAL NOTE power requirements use the The theoretical gallons per revolution following formul gal rev is 0 000870 To find specific outputs at various RPM use the formula GPM 0 000870 x RPM Intermittent duty only HP GPM X PSD 1450 P200A SERIES REPAIR KITS Plunger Packing Kit Valve Assembly Kit Part 09164 Excluding P223 Part 09116 Item Qty Part Description Item Qty Part Description 23 3 08477 V Sleeve weep 32X 6 07946 Valve Assembly Complete 23A 3 08087 V Sleeve brown 31 6 07853 O Ring A 3 07904 Pressure Ring Plunger Packing Kit Oil Seal Kit Part 09525 P223 Only Part 09144 Item Qty Part Description Item Qty Part Description 23 6 06315 V Sleeve 19 3 08356 0010 Oil Seal A 3 06920 Pressure Ring Teflon Plunger Packing Kit Part 09164 0020 Excluding P223 Item Qty Part Description 23 6 08087 0020 V Sleeve 2 3 07904 Pressure Ring P200A SERIES TORQUE SPECIFICATIONS Position Item Description Torque Amount 16C 08456 07778 Tension Screw Plunger 220 in Ibs 32 07928 Valve Plug 33 or 59 ft Ibs 34 08316 Hex Head Cap Screw Valve Casing 105 in Ibs For pumps manufactured prior to 5 97 tighten plugs to 33 ft lbs Otherwise tighten to 59 ft Ibs MALFUNCTION The Pressure and or the Delivery Drops Waterin crankc
12. g Cover I Sight Glass ExcludingP217 amp P223 Lid P217 amp P223 Only O Ring ExcludingP217 amp P223 Screw with Lock Washer Radial Shaft Seal Ball Bearing Ball Bearing Crankshaft P217A Crankshaft P218A Crankshaft P219A Crankshaft P220A Crankshaft P221 Crankshaft P223 Woodruff Key Connecting Rod WO e Fi Fi bei KF Fi Fi KF e KS OF Plunger Complete 18mm ExcludingP223 Plunger Complete 16mm P223 Only 3 Plunger Base Excluding P223 3 Plunger Base P223 Only 3 PARTNO 08455 07778 08456 07676 08442 07770 08356 0010 08444 06563 08443 08477 06315 08087 07904 06290 08445 06564 06582 06565 07849 07491 07906 07907 07853 07928 07946 07913 08316 13338 08486 07109 07661 DESCRIPTION QTY Plunger Pipe Excluding P223 Plunger Pipe P223 Only Tension Screw Copper Gasket Wrist Pin O Ring OilSeal Seal Case Excluding P223 Seal Case P223 Only O Ring V Sleeve Weep Excluding 223 V Sleeve P223 Only V Sleeve Brown ExcludingP223 Pressure Ring ExcludingP223 Pressure Ring P223 Only Weep Return Ring ExcludingP223 3 Weep Return Ring P223 Only 3 Valve Casing Excluding P223 1 2 Inlet Ports Valve Casing P223 Only Valve Seat Valve Plate Valve Spring Valve Spring Retainer O Ring Valve Plug Valve Assembly Complete O Ring Hex Head Cap Screw Plug 3 8 BSP Copper Crush Washer 3 8 Plug 1 2 BSP Seal
13. 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 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 P217A p to 3 4 GPM Discharge Pressure Continuous Jp to 2000 PSI Discharge Pressure Intermittent Jp to 2320 PSI Inlet Pressure 4 to 140 PSI Jp to 3450 RPM 5mm Temperature of Pumped Fluids Jp to 160 F Inlet Ports 2 1 2 BSP Discharge Ports 2 3 8 BSP Shaft Rotation Top of Pulley Towards Fluid End Crankshaft Diameter Key Width Shaft Mounting Right Side Facing Manifold 11 Ibs 1102 Crankcase Oil Capacity Extended Crankcase Oil Capacity Volumetric Efficiency 3450 RPM Mechanical Efficiency 3450 RPM Consult the factory for special requirements that must be met if the
14. lso 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 engine power outputs must be P221A HORSEPOWER REQUIREMENTS RPM GPM 1000 PSI 1500 PSI 2000 PSI 2320 PSI 1750 Intermittent duty only SPECIAL NOTE The theoretical gallons per revolution gal rev is 0 00126 To find specific outputs at various RPM use the formula GPM 0 00126 x RPM 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 Exploded View P200A Series ka ER x o W co ec os O N 0 o gt N 0 o P200A SERIES PARTS LIST PARTNO DESCRIPTION 08300 08301 08480 08302 08302 L 07190 08005 06273 08192 07188 01176 2 08303 08490 08439 08492 07225 01166 08020 01020 08465 08440 08466 08467 12258 06547 06207 08333 08469 06561 08468 06562 Crankcase Dipstick and Gasket Black Except P217 amp P223 Dipstick and Gasket Red P217 amp P223 Crankcase Cover Short Crancase Cover Long Drain Plug amp Gasket O Ring Oil Drain Plug Gasket Screw Crankcase Cover Spring Washer A A e Fa Fa me Fi m eS Bearin
15. ntermittent duty only We recommend a 1 15 service factor be specified when selecting an electric motor as the power source To compute specific pump horse SPECIAL NOTE power requirements use the The theoretical gallons per revolution following formula gal rev is 0 00266 To find specific outputs at various RPM use the formula GPM 0 00266 x RPM HP GPM X PSD 1450 Specifications Model P221A Jp to 2 21 GPM Jp to 2000 PSI Jp to 2320 PSI 4 35 to 140 PSI Jp to 1750 RPM Discharge Pressure Continuous Discharge Pressure Intermittent Inlet Pressure Omm Jp to 160 F 2 1 2 BSP 2 3 8 BSP Top of Pulley Towards Fluid End Temperature of Pumped Fluids Inlet Ports Discharge Ports Shaft Rotation Crankshaft Diameter Key Width Shaft Mounting Right Side Facing Manifold 11 lbs 11oz Crankcase Oil Capacity Extended Crankcase Oil Capacity Volumetric Efficiency 1750 RPM Mechanical Efficiency 1750 RPM 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 crank case 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 a
16. ollowing formula To find specific outputs at various RPM use the formula GPM 0 00239 x RPM HP GPM X PSD 1450 Specifications Model P220A p to 4 7GPM Discharge Pressure Continuous Jp to 2000 PSI Discharge Pressure Intermittent Jp to 2320 PSI Inlet Pressure 4 to 140 PSI Jp to 1750 RPM Temperature of Pumped Fluids Inlet Ports Discharge Ports Shaft Rotation Crankshaft Diameter Key Width Shaft Mounting Right Side Facing Manifold Weight 11 Ibs 1107 Crankcase Oil Capacity Extended Crankcase Oil Capacity Volumetric Efficiency 1750 RPM Mechanical Efficiency 1750 RPM 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 crank case 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 P220A HORSEPOWER REQUIREMENTS jcquirements for the pump Gas RPM GPM 1000 PSI 1500 PSI 1700 Fal 2000 PSF 2320 PSF engine power outputs must be T T m A 25 2 approximately twice the pump 1750 u nn I
17. p to 2320 PSI Inlet Pressure 4 35 to 140 PSI Up to 1750 RPM Temperature of Pumped Fluids Inlet Ports 2 1 2 BSP Discharge Ports 2 3 8 BSP Shaft Rotation Top of Pulley Towards Fluid End Crankshaft Diameter Key Width Shaft Mounting Right Side of Manifold i 11 lbs 1102 Crankcase Oil Capacity Extended Crankcase Oil Capacity Volumetric Efficiency 1750 RPM Mechanical Efficiency 1750 RPM 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 crank case 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 P219A HORSEPOWER REQUIREMENTS The rating shown are the power requirements for the pump Gas engine power outputs must be approximately twice the pump power requirements shown above 1750 Intermittent duty only We recommend a 1 15 service factor be specified when selecting an electric motor as the power source SPECIAL NOTE To compute specific pump horse The theoretical gallons per revolution power requirements use the gal rev is 0 00239 f
18. rea 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 7 amp page 10 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 regard to its potential hazard it can cause serious
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