Giant P217-3100, P220-3100, P200-3100 SERIES, P218-3100, P219-3100 Operating Instructions/ Repair And Service Manual

P200-3100

SERIES PUMPS

18mm Versions

Nickle-Aluminum Bronze Models:

P217-3100, P218-3100, P219-3100,
P220-3100, P221-3100, P227-3100,
P230-3100

Triplex Ceramic

Plunger Pump

Operating Instructions/

Repair and Service Manual

Updated 11/11

Contents:

Installation Instructions: page 2

Pump Specications: page 3

Exploded View: page 4
Parts List / Kits: page 5

Torque Specications: page 5

Repair Instructions: pages 6-7
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 at 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

ow rate of the pump with no unnecessary re-

strictions that can cause cavitation. Teon 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 ow rate to pre­vent line pressure loss to the work area. It is es-

sential 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.

0

4. Use of a dampener is necessary to minimize

pulsation at drive elements, plumbing, con-

nections, 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 fol-

lowing a few guidelines available upon request

from Giant Industries, Inc. Required horsepower
for system operation can be obtained from the
charts on pages 3-9.

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. Cavi-

tation will result in severe damage. Always
remember to check that all plumbing valves are
open and that pumped media can ow 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 crank-

case so that oil level is between the two lines on
the oil dipstick. DO NOT OVERFILL.

Use Giant recommended Oil
P/N 01153 (20W-50)

2. Pump operation must not exceed rated pres-

sure, volume, or RPM. A pressure relief device

must be installed in the discharge of the system.

3. Acids, alkalines, or abrasive uids cannot be

pumped unless approval in writing is obtained

before operation from Giant Industries, Inc.

Crankcase oil should be changed after the

rst 50 hours of operation, then at regular inter­vals of 500 hours or less depending on operat-

ing conditions.

4. Run the pump dry approximately 10 seconds
to drain the water before exposure to freezing

temperatures.

2

Horsepower Ratings:

U.S. Measurements

Max. Flow

Maximum
Pressure

Max.

Speed

Power
Req'd.

Max.

Temperature

Plunger

Diameter

Stroke

NPSH

Required

Model GPM PSI RPM BHP F in in Ft-Head

P230-3100 1.1 2000 1750 1.5 86 0.71 0.13 n/a
P217-3100 1.85 2000 1750 2.6 86 0.71 0.22 n/a
P227-3100 2.1 2000 1750 2.9 86 0.71 0.25 n/a
P230-3100 2.1 2000 3450 2.9 86 0.71 0.13 n/a
P221-3100 2.34 2000 1750 3.32 86 0.71 0.28 n/a
P218-3100 3.4 2000 1750 4.7 86 0.71 0.39 21.0
P217-3100 3.6 2000 3450 5 86 0.71 0.42 n/a
P227-3100 3.8 2000 3450 5.2 86 0.71 0.25 n/a
P219-3100 4.2 2000 1750 5.8 86 0.71 0.49 21.0
P220-3100 4.7 2000 1750 6.5 86 0.71 0.56 21.6

Metric Measurements

Max. Flow

Maximum
Pressure

Max.

Speed

Power
Req'd.

Max.

Temperature

Plunger

Diameter

Stroke

NPSH

Required

Model L/min Bar RPM kW C mm mm mWs

P230-3100 4.2 140 1750 2.0 30 18 3.4 n/a
P217-3100 7.0 140 1750 3.5 30 18 5.5 n/a
P227-3100 7.9 140 1750 3.9 30 18 6.3 n/a
P230-3100 7.9 140 3450 3.9 30 18 3.4 n/a
P221-3100 8.9 140 1750 4.5 30 18 7 n/a
P218-3100 12.9 140 1750 6.3 30 18 10 6.4
P217-3100 13.6 140 3450 6.7 30 18 5.5 n/a
P227-3100 14.4 140 3450 7.0 30 18 6.3 n/a
P219-3100 15.9 140 1750 7.8 30 18 12.4 6.4
P220-3100 17.8 140 1750 8.7 30 18 14.1 6.6

P200-3100 Series - 18mm Versions- Pump Specifications

We recommend a 1.15 service factor be specied when selecting an electric motor as the power source.

To compute electric motor horsepower required, use the following formula: HP = (GPM X PSI) / 1450.

The formula to determine the horsepower required for a gas engine is: HP = (GPM X PSI) / 1150.
The formula to determine the horsepower required for a diesel engine is: HP = (GPM X PSI) / 1250.

For the Application of a Hydraulic Motor:
To Determine the Torque of a Hydraulic Motor -- (GPM x PSI x 36.77) / RPM = Torque (in-lbs)

Calculating RPM / GPM of Pump:
A pump must be connected to an electric motor or gas or diesel engine with the correct ratio of pulleys

and belts to attain the required speed and GPM. The use of a Variable Frequency Drive (VFD) may also
be used to control the RPM of a properly sized electric motor when variable ows are required.

(Max. Pump RPM / Rated Pump GPM) x Required Pump GPM = Required Pump RPM
To calculate a pulley diameter one (1) pulley diameter and the required pump RPM must be known:

(Pump RPM x Pump Pulley Diameter) / Motor RPM = Motor Pulley Diameter
(Motor RPM x Motor Pulley Diameter) / Pump RPM = Pump Pulley Diameter

Materials Used for P200-3100 Pumps:

Manifold ........ Nickle-Aluminum Bronze

Plungers .......Solid Ceramic Oxide

Valves ............. 316 Stainless Steel

Seals............... Nitrile with Fabric Reinforcing

Gear End ...... Anodized Aluminum

Common Specications:

Max. Inlet Pressure..............145 PSI (10 Bar)

Crankshaft Diameter............0.94” (24mm)

Oil Capacity (short) ..............7.5 . oz. (0.2 L)

Oil Capacity (extended) .......9.0 . oz. (0.3 L)

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

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

Weight .................................13.4 lbs (6.0 kg)

Shaft Rotation Top of Pulley Towards Fluid End

3

Exploded View - P200A-3100 Series

4

P200A-3100 SERIES PARTS LIST

ITEM PART NO. DESCRIPTION QTY.

1 08300A Crankcase, Anodized 1
2 08301 Dipstick 1
3 08302A Crankcase Cover, Anodized 1
3 08302-L Crankcase Cover,
Long (Optional) 1
3A 07190-0100 Drain Plug & Gasket 1
4 08005 O-Ring 1
5 08185-0100 Oil Drain Plug with seal 1
5A 08192 Gasket 1
6 07188-0100 Screw, 316 S.S. 4
6A 07223-0100 Spring Washer, 316 S.S. 4
7 08303 Bearing Cover I 2
8 08490 Sight Glass 1
9 08492 O-Ring 1
10 07225-0100 Screw 8
10A 07223-0100 Spring Washer 8
11 01166 Radial Shaft Seal 1
12A 08020 Ball Bearing 1
12B 01020 Ball Bearing 1
13 08465 Crankshaft (P217A-3100) 1
13 08440 Crankshaft (P218A-3100) 1
13 08466 Crankshaft (P219A-3100) 1
13 08467 Crankshaft (P220A-3100) 1
13 12258 Crankshaft (P221A-3100) 1
13 06547 Crankshaft (P227A-3100) 1
13 06694 Crankshaft (P230A-3100) 1
14 06207 Fitting Key 1
15 08333 Connecting Rod 3
16 08469-0100 Plunger Assembly, 3
Except P230-3100
16 06641-0100 Plunger Assembly 3
P230-3100 Only
16A 08468-0100 Plunger Base, 316 S.S. 3
16B 08455 Plunger Pipe 3

ITEM PART NO. DESCRIPTION QTY.

16C 08456-0100 Tension Screw, 316 S.S. 3
16D 07204-0100 Crush Washer, 316 S.S. 3

16E 07203 Support Ring, 3

16F 07023 O-Ring, 3
16G 06823 Plunger Extension, 3
P230-3100 Only
17 08442 Wrist Pin 3
19 08356 Oil Seal 3
20 08444A-0100 Seal Retainer, 316 S.S. 3
21 12260-0001 O-Ring 3
23 06704* Grooved Seal 3
23A 08087 Grooved Seal Ring, Brown 3
23B 06163 Drip Shield 3
24 07904 Pressure Ring 3
25 08445-0100 Weep Return Ring, 316 S.S. 3
26 06582-3000 Valve Casing 1
26A 07946-0100 Valve Assembly,(27-30/31/33)
Except P230-3100 6
27 07849-0100 Valve Seat 6
28 06809 Valve Plate 6

29 07906-0100 Valve Spring, except P230-3100 6
29 06816 Valve Spring, P230-3100 Only 6

30 07907 Valve Spring Retainer 6
30A 06824 Spacer Ring, P230-3100 Only 3
31 7853-0001 O-Ring 6
32 07928-0300 Plug 6
33 07913-0001 O-Ring 6
34 08316-0100 Hex Head Cap Screw 8
37 13338-0300 Plug, 3/8” BSP 1
37A 08486 Copper Washer, 3/8” 1
38 07109-0300 Plug, 1/2” BSP 1
38A 06272 Copper Washer, 1/2” 1

*p/n 08477 might also be used in this position

P200A-3100 SERIES REPAIR KITS

Plunger Packing Kit
Part# 09602

Item Part # Description Qty.

23 08477* Grooved Seal 3
23A 08087 Grooved Seal Ring 3
23B 06163 Drip Shield 3
24 07904 Pressure Ring 3

*p/n 06704 can also be used in this position

Oil Seal Kit
Part# 09144

Item Part # Description Qty.

19 08356 Oil Seal 3

Valve Assembly Kits
Part # 09714 - Except P230-3100

Item Part # Description Qty.

26A 07946-0100 Valve Assembly 6
33 07913-0001 O-Ring 6

Part # 09139 - P230-3100 Only

Item Part # Description Qty.

27 07849-0100 Valve Seat 6
28 06809 Valve Plate 6
29 06816 Valve Spring 6
30 07907 Valve Retainer 6
31 07853-0001 O-Ring 6
33 07913-0001 O-Ring 6

P200A-3100 SERIES TORQUE SPECIFICATIONS

Position Item# Description Torque Amount

16C 08456-0100 Tension Screw, Plunger 220 in-lbs. (24.9 NM)
32 07928-0100 Valve Plug 33 ft-lbs (44.7 NM)
34 08316-0100 Hex Head Cap Screw, Valve Casing 105 in.-lbs. (11.8 NM)

5

REPAIR INSTRUCTIONS - P200A-3100 SERIES

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. Apply one drop of Loctite
243 to the valve plugs (32)
and tighten to 33 ft.-lbs.

2. Using a needle nose pliers,

remove the inlet and dis-

charge valve assemblies

(27-30), for P230-3100 only,

remove spacer (30A), and

o-ring (31). Inspect all parts

for wear and replace as nec­essary.

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).
Remove the rear v-sleeve
(23A) from the seal case

(20). Inspect all parts, in-

cluding o-ring (21) for wear

and replace as necessary.

8.Check surfaces of plunger pipe
(16B). A damaged surface will cause

accelerated wear on the seals. De-

posits of any kind must be carefully

removed from the plunger surface. A

damaged plunger must be replaced!

When replacing the crush washer
(item 16D), make sure the rolled side
of the crush washer is placed on the
ceramic. Prior to installation, care­fully crush the seal ring on a hand
press.

6

9. If the crankcase oil seals
(19) are to be replaced,
they can be removed by
prying loose with a at

screwdriver. Take care not

to make contact with the

plunger.

REPAIR INSTRUCTIONS - P200A-3100 SERIES

Disassembly sequence of the back end of the P200A-3100 series pump.

1) Before you begin, drain the oil from the crankcase.

2) Remove the crankcase cover (3) and o-ring (4) from the crankcase (1). To remove the crankshaft (13),
remove the bearing cover (7) and sight glass (8). Using a rubber mallet, remove the crankshaft axially

through the connecting rods by tapping on the end of the shaft. Be careful not to bend or damage the con-

necting rods during crankshaft removal.

3) If the bearings (12A and 12B) and radial shaft seal (11) are still in the crankcase, remove them. Inspect
both bearings and seal for wear and replace if necessary.

4) Remove the connecting rod (15) and plunger assembly (16). Remove the wrist pin (17) if necessary.
Check the plunger bore in the crankcase for wear. Inspect parts and replace as necessary.

5) Should you nd it necessary to service the plunger assembly (16) you can do so by removing the tension

screw (16C). Replace crush washer (16D). NOTE: Carefully atten crush washer before replacing it.

Inspect all parts and replace as necessary.

Reassembly sequence of the P200A-3100 series pump

1) Reassemble plunger assembly (16) (apply a drop of Loctite to the tension screw (16C) threads) and the

connecting rod (15) with wrist pin (17). Place assemblies in crankcase (1). Install crankshaft through con-

necting rods again being careful not to bend or otherwise damage the connecting rods.

2) Replace left and right side bearings (12A and 12B) if they were removed from the crankshaft. Be certain
the bearings are pressed all the way onto the shaft and completely into the crankcase. Replace radial shaft
seal (11), bearing cover (7), sight glass (8), and crankcase cover (3) with its o-ring (4).

3) If oil seals (19) were removed, replace with seal lip towards crankcase. Lubricate seal before replacing.

4) Replace seal case (20) with o-rings (21) over plungers. Generously lubricate o-rings and oil seal before
reassembly. Replace drip shield (23B) and v-sleeve (23A) over plungers (16)..

5) Generously lubricate v-sleeve (23) and assemble into valve casing (26). Assemble weep return ring (25)
and pressure ring (24) over plungers (16). Slide valve casing over plungers and seat rmly. Replace the
eight socket head cap screws (34) and tighten to 105 inch-pounds in a crossing pattern (see below).

6) Re-install the six o-rings (31) and the six valve assemblies (27-30), and spacer ring (16D), P230-3100 only.
Now replace the six valve plugs with o-rings (32 and 33) and tighten securely with a 22mm socket wrench
to 33 foot-pounds.

7) Fill crankcase with 8.1 ounces of oil.

Pump Mounting Selection Guide

Bushings
07174 - 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=5.75”x W-1.0”XH=1.812”)

01161 - Plated Steel Channel Rails (L=5.75”x W-1.0”XH=2.50”)

5

3

1

8

7

2

4

6

7

P200A-3100 DIMENSIONS - INCHES (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 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 ve 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 manufac-

turer’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 modications made by the customer or third party.

6. The operation of pumps and or accessories exceeding the specications 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 work-

manship 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 war-

ranty consideration. Call (419)-531-4600 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 WAR-

RANTIES 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., Toledo, Ohio 43607
Phone [phone], Fax [phone], www.giantpumps.com
 Copyright 2010 Giant Industries, Inc.

11/11 P200-3100.indd