Series
CP200
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 & Torque Specifications: page 8
Pump Mounting Selection
Guide: page 8
Repair Instructions: 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 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
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, 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 Oil or Use SAE 0 W 40 when
pumping CO
under 32oF (0o C)
2
3. Acids, alkalines, or abrasive fluids cannot be
pumped unless approval in writing is obtained
Crankcase oil should be changed after the
before operation from Giant Industries, Inc.
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
Specifications
Model CP218
Ratings ........................................................................................................ 1.4 GPM @ 2030 PSI
Inlet Pressure .............................................................................................. 14 to 140 PSI
RPM ........................................................................................................... Up to 750 RPM
Plunger Diameter ........................................................................................ 18mm
Stroke .......................................................................................................... 10mm
Temperature of Pumped Fluids ................................................................... -40
Inlet Ports ................................................................................................... (2) 3/8" BSP
Discharge Ports .......................................................................................... (2) 3/8" BSP
Shaft Rotation ................................................................................ Top of Pulley Towards Fluid End
Crankshaft Diameter .................................................................................. 24mm
Key Width ................................................................................................... 8m m
Shaft Mounting ........................................................................................... Right Side Facing Manifold
Weight ......................................................................................................... 11 lbs. 11oz.
Crankcase Oil Capacity .............................................................................. 7.5 fl.oz.
Extended Crankcase Oil Capacity .............................................................. 9.0 fl.oz.
+
Positive inlet pressure required
o
F to 160oF
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 to the repair instructions as necessary for
the proper assembly sequence.
HORSEPOWER RATINGS:
The rating shown are the power
CP218 HORSEPOW ER REQUIREMENTS
RPM GPM 500 PSI 1000 PSI 1500 PS I 2030 PSI
200 0.4 0.1 0.3 0.4 0.6
300 0.6 0.2 0.4 0.6 0.8
400 0.7 0.2 0.5 0.7 1.0
500 0.9 0.3 0.6 0.9 1.3
600 1.1 0.4 0.8 1.1 1.5
750 1.4 0.5 1.0 1.4 2.0
requirements for the
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
power requirements, use the
following formula:
pump. Gas
HP = (GPM X PSI) / 1450
3
Specifications
Model CP220
Ratings ........................................................................................................ 1.9 GPM @ 2030 PSI
Inlet Pressure .............................................................................................. 14 to 140 PSI
RPM ........................................................................................................... Up to 750 RPM
Plunger Diameter ........................................................................................ 18mm
Stroke .......................................................................................................... -40
Inlet Ports ................................................................................................... (2) 3/8" BSP
Discharge Ports .......................................................................................... (2) 3/8" BSP
Shaft Rotation ................................................................................ Top of Pulley Towards Fluid End
Crankshaft Diameter .................................................................................. 24mm
Key Width ................................................................................................... 8m m
Shaft Mounting ........................................................................................... Right Side Facing Manifold
Weight......................................................................................................... 11 lbs. 11oz.
Crankcase Oil Capacity .............................................................................. 7.5 fl.oz.
Extended Crankcase Oil Capacity .............................................................. 9.0 fl.oz.
o
to 160oF
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
fill and the oil drain plugs, also. Refer to the repair instructions as necessary for
the proper assembly sequence.
CP220 HO RSEPOWER REQUIREMENTS
RPM GPM 500 PSI 1000 PSI 1500 PSI 2030 PSI
200 0.5 0.2 0.3 0.5 0.7
300 0.8 0.3 0.6 0.8 1.1
400 1.0 0.3 0.7 1.0 1.4
500 1.3 0.4 0.9 1.3 1.8
600 1.5 0.5 1.0 1.6 2.1
750 1.9 0.7 1.3 2.0 2.7
down at the six o'clock position. Exchange the oil
HORSEPOWER RATINGS:
The rating shown are the power
requirements for the
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
power requirements, use the
following formula:
pump. Gas
HP = (GPM X PSI) / 1450
4
Specifications
Model CP230
Ratings ........................................................................................................ 0.5 GPM @ 2030 PSI
Inlet Pressure .............................................................................................. 14 to 140 PSI
RPM ........................................................................................................... Up to 750 RPM
Plunger Diameter ........................................................................................ 18mm
Stroke .......................................................................................................... 3.4mm
Temperature of Pumped Fluids ................................................................... -40
Inlet Ports ................................................................................................... (2) 3/8" BSP
Discharge Ports .......................................................................................... (2) 3/8" BSP
Shaft Rotation ................................................................................ Top of Pulley Towards Fluid End
Crankshaft Diameter .................................................................................. 24mm
Key Width ................................................................................................... 8m m
Shaft Mounting ........................................................................................... Right Side Facing Manifold
Weight......................................................................................................... 11 lbs. 11oz.
Crankcase Oil Capacity .............................................................................. 7.5 fl.oz.
Extended Crankcase Oil Capacity .............................................................. 9.0 fl.oz.
+
Positive inlet pressure required
o
to 160oF
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 to the repair instructions as necessary for
the proper assembly sequence.
HORSEPOWER RATINGS:
The rating shown are the power
CP230 HO RSEPOWER REQUIREMENTS
requirements for the
engine power outputs must be
RPM GPM 500 PSI 1000 PSI 1500 PSI 2030 PSI
200 0.1 0.0 0.1 0.1 0.1
300 0.2 0.1 0.1 0.2 0.3
400 0.3 0.1 0.2 0.3 0.4
500 0.3 0.1 0.2 0.3 0.4
600 0.4 0.1 0.3 0.4 0.6
750 0.5 0.2 0.3 0.5 0.7
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:
pump. Gas
HP = (GPM X PSI) / 1450
5
Exploded View
CP200 Series
6
Spare Parts
CP200 Series
ITEM PART NO. DESCRIPTION QTY.
1 08300 Crankcase 1
2 06773 Oil Dipstick with O-Ring 1
3 08302 Crankcase Cover, Short 1
3 08302-L Crancase Cover, Long 1
3A 07190 Drain Plug & Gasket 1
4 08005 O-Ring 1
5 06273 Oil Drain Plug 1
5A 08192 Gasket 1
6 07188 Screw, Crankcase Cover 4
6A 07223-0100 Spring Washer 4
7 08303 Bearing Cover I 2
8 08490 Oil Sight Glass 1
9 08492 O-Ring 1
10 07225 Screw with Lock Washer 8
ITEM PART NO. DESCRIPTION QTY.
16C 08456 Tension Screw 3
16D 07676 Copper Gasket 3
16D 07204-0100 Copper Gasket (CP230 only) 3
16E 06823 Pl unger Extension (CP230 only) 3
17 08442 Wrist Pin 3
18 07770 O-Ring 3
19 08356-0010 Oil Seal 3
20 08444 Seal Case 3
21 06815 O-Ring 3
23 08087 V-Sleeve, Weep 3
23A 08087-0020 V-Sleeve, Teflon 3
24 07904 Pressure Ring 3
25 08445 Weep Return Ring 3
26 08446 Valve Casing 1
11 01166 Radial Shaft Seal 1
12 A 08020 Ball Bearing 1
12B 01020 Ball Bearing 1
13 08440 Crankshaft (CP218) 1
13 08467 Crankshaft (CP220) 1
13 06694 Crankshaft (CP230) 1
14 06207 Woodruff Key 1
15 08333 Connecting Rod 3
16 08469 Plunger, Complete, 18mm 3
16 A 08468 Plunger Base 3
16B 08455 Plunger Pipe 3
27 07849 Valve Seat 6
28 06809 Valve Plate 6
29 06816 Valve Spring 6
30 07907 Valve Spring Retainer 6
30 A 06824 Spacer Ring (CP230 only) 3
31 06817 O-Ring 6
32 079 28 Valve Plug 6
32X 06825 Valve Assembly 6
33 06818 O-Ring 6
34 08316 Hex Head Cap Screw 8
38 13338 Plug, 3/8" BSP 1
7
Repair Kits
CP200 Series
Plunger Packing Kit
Part # 09554
Item # Part # Description Qty.
23 08087 V-Sleeve, weep 3
23A 08087-0020 V-Sleeve, brown 3
24 07904 Pressure Ring 3
Valve Assembly Kit
Part # 09556
Item # Part # Description Qty.
27 07849 Valve Seat 6
28 06809 Valve Plate 6
29 06816 Valve Spring 6
30 07907 Valve Spring Retainer 6
31 06817 O-Ring 6
Pump Torque Specifications
Oil Seal Kit
Part # 09144
Item # Part # Description Qty.
19 08356-0010 Oil Seal 3
CP200 Series
Position Item# Description Torque Amount
16C 08456 Tension Screw, Plunger 220 (in.-lbs.)
32 07928 Valve Plug 59 (ft.-lbs.)
34 08316 Hex Head Cap Screw, Valve Casing 105 (in.-lbs.)
Pump Mounting Selection Guide
Bushings
01074 - 24 mm Tapered H Bushing
Pulley & 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=5.75x W=1.00x h=2.50)
01161 - Plated Steel Channel Rails
(L=5.75x W=1.00x H=2.50)
8
REPAIR INSTRUCTIONS - CP200 PUMPS
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
wrench, remove the (3)
discharge valve plugs and
(3) inlet valve plugs (32)
Inspect the o-ring (33) for
wear and replace if
damaged.
4. 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.-lbs.
2. Using a needle nose pliers,
remove the inlet and
discharge valve assemblies
(27-31).
5. Next, use a 5mm allen
wrench to remove the 8
socket head cap screws
(34).
3. By inserting a small screw
driver between the valve
seat (27) and the valve
spring retainer (30), the
valve assembly can be
separated.
6. Carefully slide the valve
casing (26) out over the
plungers.
7. 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.
Remove the v-sleeve
(23A) from the seal case
(20). Inspect all parts,
including o-ring (21) for
wear and replace as
necessary
8. Check surfaces of plunger
(16). A damaged surface
will cause accelerated
wear on the seals. Deposits of any kind must be
carefully removed from
the plunger surface. A
damaged plunger must be
replaced!
9
9. 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
(16B) is damaged, remove
the plunger bolt (16C) and
plunger extension (16ECP230 only). Discard the
old plunger pipe (16B)
and copper gasket (16D).
Clean the old locktite from
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.
NOTE: If there are
deposits of any kind (i.e.,
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 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 casing over plungers and seat firmly. Replace the eight
socket head cap screws (34) and tighten to 105 inch-pounds in a crossing pattern.
4) 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.-lbs.
NOTE: Contact Giant Industries for Service School Information. Phone: (419)-531-4600
10
PUMP SYSTEM MALFUNCTION
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 Drop at
g un flow rate of pump Rated,
Pressure
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
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 Quart) p/n 1153 X X
Seal Spare Parts (1 kit/pump) X
(See page 8 for kit list)
Oil Seal Kit (1 kit/pump) X
(See page 8 for kit lit)
Valve Spare Parts (1 kit/pump) X
(See page 8 for kit list)
11
CP200 SERIES DIMENSIONS (inches)
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:
This warranty is limited to repair or replacement of pumps and accessories of which the
manufacturers evaluation shows were defective at the time of shipment by the manufacturer. The
following items are NOT covered or will void the warranty:
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
under warranty consideration. Call (419)-531-4600 or fax (419)-531-6836 to obtain an R.G.A.
number.
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 applications, are warranted for five years from the date of shipment for all pumps used in NONSALINE, 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.
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.
prior to the return to Giant Industries of all products
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 (419) 531-4600, FAX (419) 531-6836, www.giantpumps.com
Ó Copyright 2002 Giant Industries, Inc.
4/02 CP200.PM6
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