Giant P200A User Manual

Series
P200A

Triplex Ceramic
Plunger Pump
Operating Instructions/
Repair and Service
Manual

For Models:
P217
P218
P219
P220
P221
P223

Updated 3/01

Contents:

Installation Instructions: page 2
Pump Specifications: pages 3-7, 10
Exploded View: page 8
Parts List: page 9
Kits & Torque Specifications: page 1 1
Trouble Shooting: page 1 2
Repair Instructions: 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 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 3-7 & 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, 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

3. Acids, alkalines, or abrasive fluids cannot be

Crankcase oil should be changed after the

first 50 hours of operation, then at regular

pumped unless approval in writing is obtained

before operation from Giant Industries, Inc.
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

Volume ........................................................................................................ Up to 3.4 GPM

Model P217A

Discharge Pressure (Continuous) ............................................................... Up to 2000 PSI

Discharge Pressure (Intermittent) .............................................................. Up to 2320 PSI*

Inlet Pressure .............................................................................................. 14 to 140 PSI

RPM ........................................................................................................... Up to 3450 RPM

Plunger Diameter ........................................................................................ 18mm

Stroke .......................................................................................................... 5.5mm

Temperature of Pumped Fluids ................................................................... Up to 160

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

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

Shaft Rotation ................................................................................ Top of Pulley Towards Fluid End

Crankshaft Diameter .................................................................................. 24mm

Key Width ................................................................................................... 8 m 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.

Volumetric Efficiency @ 3450 RPM .......................................................... 0.88

Mechanical Efficiency @ 3450 RPM......................................................... 0.86

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.

o

F

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.

P217A HO RSEPOWER REQUIREMENTS

RPM GPM 1000 PSI 1500 PSI 2000 PSI 2320 PSI*
1725 1.7 1.2 1.8 2.3 2. 7
3000 3.0 2.1 3.1 4.2 4. 8
3200 3.2 2.2 3.3 4.4 5. 1
3450 3.4 2.3 3.5 4.7 5. 4

*Intermittent duty only

SPECIAL NOTE:

The theoretical gallons per revolution
(gal/rev) is 0.0009855.
To find specific outputs at various RPM,
use the formula: GPM =0.0009855xRPM

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:

HP = (GPM X PSI) / 1450

pump. Gas

3

Specifications

Volume ........................................................................................................ Up to 3.4 GPM

Model P218A

Discharge Pressure (Continuous) ............................................................... Up to 2000 PSI

Discharge Pressure (Intermittent) .............................................................. Up to 2320 PSI*

Inlet Pressure .............................................................................................. - 4.35 to 140 PSI

RPM ........................................................................................................... Up to 1750 RPM

Plunger Diameter ........................................................................................ 18mm

Stroke .......................................................................................................... 10.0mm

Temperature of Pumped Fluids ................................................................... Up to 160

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

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

Shaft Rotation ................................................................................ Top of Pulley Towards Fluid End

Crankshaft Diameter .................................................................................. 24mm

Key Width ................................................................................................... 8 m 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.

Volumetric Efficiency @ 1750 RPM .......................................................... 0.96

Mechanical Efficiency @ 1750 RPM......................................................... 0.85

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.

down at the six o'clock position. Exchange the oil

o

F

P218A HORSEPOWER REQUIREMENTS

RPM GPM 1000 PSI 1500 PSI 2000 PSI 2320 PSI*
1150 2.2 1.5 2.3 3.1 3. 6
1450 2.8 1.9 2.9 3.9 4. 5
1750 3.4 2.3 3.5 4.7 5. 4

*Intermittent duty only

SPECIAL NOTE:

The theoretical gallons per revolution
(gal/rev) is 0.00193.
To find specific outputs at various RPM,
use the formula: GPM = 0.00193 x RPM

4

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:

HP = (GPM X PSI) / 1450

pump. Gas

Specifications
Model P219A

Volume ............................................................................................................ Up to 4.2 GPM

Discharge Pressure (Continuous) ................................................................... Up to 2000 PSI

Discharge Pressure (Intermittent) .................................................................. Up to 2320 PSI*

Inlet Pressure .................................................................................................. - 4.35 to 140 PSI

RPM ................................................................................................................ Up to 1750 RPM

Plunger Diameter ............................................................................................ 18mm

Stroke .............................................................................................................. 12.4mm

Temperature of Pumped Fluids ....................................................................... Up to 160

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

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

Shaft Rotation .................................................................................... Top of Pulley Towards Fluid End

Crankshaft Diameter....................................................................................... 24mm

Key Width ....................................................................................................... 8 mm

Shaft Mounting ................................................................................................ Right Side of Manifold

Weight ............................................................................................................. 11 lbs. 11oz.

Crankcase Oil Capacity .................................................................................. 7.5 fl.oz.

Extended Crankcase Oil Capacity .................................................................. 9.0 fl.oz.

Volumetric Efficiency @ 1750 RPM .............................................................. 0.96

Mechanical Efficiency @ 1750 RPM ............................................................. 0.85

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.

o

F

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.

P219A HORSEPOWER REQUIREMENTS

RPM GPM 1000 PSI 1500 PSI 2000 PSI 2320 PSI*
1150 2.7 1.9 2.8 3.8 4.4
1450 3.5 2.4 3.6 4.8 5.5
1750 4.2 2.9 4.3 5.8 6.7

*Intermittent duty only

SPECIAL NOTE:

The theoretical gallons per revolution
(gal/rev) is 0.00239.
To find specific outputs at various RPM,
use the formula: GPM = 0.00239 x RPM

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:

HP = (GPM X PSI) / 1450

pump. Gas

5

6.2

Specifications

Volume ............................................................................................................ Up to 4.7GPM

Discharge Pressure (Continuous) ................................................................... Up to 2000 PSI

Discharge Pressure (Intermittent) .................................................................. Up to 2320 PSI*

Inlet Pressure .................................................................................................. 14 to 140 PSI

RPM ................................................................................................................ Up to 1750 RPM

Plunger Diameter ............................................................................................ 18mm

Stroke .............................................................................................................. 14.1mm

Temperature of Pumped Fluids ....................................................................... Up to 160

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

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

Shaft Rotation .................................................................................... Top of Pulley Towards Fluid End

Crankshaft Diameter....................................................................................... 24mm

Key Width ....................................................................................................... 8 mm

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.

Volumetric Efficiency @ 1750 RPM .............................................................. 0.95

Mechanical Efficiency @ 1750 RPM ............................................................. 0.86

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.

Model P220A

o

F

P220A HORSEPOWER REQUIREMENTS

RPM GPM 1000 PSI 1500 PSI 1700 PSI 2000 PSI* 2320 PSI*
1150 3.1 2.1 3.2 3.6 4.2 4.9
1450 3.9 2.7 4.0 4.5 5.3
1750 4.7 3.2 4.8 5.5 6.4 7.4

*Intermittent duty only

SPECIAL NOTE:

The theoretical gallons per revolution
(gal/rev) is 0.00266.
To find specific outputs at various RPM,
use the formula: GPM = 0.00266 x RPM

6

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:

HP = (GPM X PSI) / 1450

pump. Gas

Specifications

Volume ........................................................................................................ Up to 2.21 GPM

Model P221A

Discharge Pressure (Continuous) ............................................................... Up to 2000 PSI

Discharge Pressure (Intermittent) .............................................................. Up to 2320 PSI*

Inlet Pressure .............................................................................................. - 4.35 to 140 PSI

RPM ........................................................................................................... Up to 1750 RPM

Plunger Diameter ........................................................................................ 18mm

Stroke .......................................................................................................... 7.0mm

Temperature of Pumped Fluids ................................................................... Up to 160

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

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

Shaft Rotation ............................................................................................. Top of Pulley Towards Fluid End

Crankshaft Diameter .................................................................................. 24mm

Key Width ................................................................................................... 8 m 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.

Volumetric Efficiency @ 1750 RPM .......................................................... 0.96

Mechanical Efficiency @ 1750 RPM......................................................... 0.85

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.

o

F

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.

down at the six o'clock position. Exchange the oil

P221A HORSEPOWER REQUIREMENTS

RPM GPM 1000 PSI 1500 PSI 2000 PSI* 2320 PSI*
1150 1.4 1.0 1.5 2.0 2.3
1450 1.8 1.3 1.9 2.5 2.9
1750 2.2 1.5 2.3 3.0 3.5

*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

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:

HP = (GPM X PSI) / 1450

pump. Gas

7

Exploded View - P200A Series

8

P200A SERIES PARTS LIST

ITEM PART NO. DESCRIPTION QTY.

1 08300 Crankcase 1

2 08301 Dipstick and Gasket, Black

(Except P217& P223) 1

2 08480 Dipstick and Gasket, Red

(P217& P223) 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 01176-2 Spring Washer 4

7 08303 Bearing Cover I 2

8 08490 Sight Glass

(Excluding P217 & P223) 1

8 08439 Lid (P217 & P223 Only) 1

9 08492 O-Ring

(Excluding P217 & P223) 1

10 07225 Screw with Lock Washer 8

11 01166 Radial Shaft Seal 1

12 A 08020 Ball Bearing 1

12B 01020 Ball Bearing 1

13 08465 Crankshaft (P217A) 1

13 08440 Crankshaft (P218A) 1

13 08466 Crankshaft (P219A) 1

13 08467 Crankshaft (P220A) 1

13 12258 Crankshaft (P221) 1

13 06547 Crankshaft (P223) 1

14 06207 Woodruff Key 1

15 08333 Connecting Rod 3

16 08469 Plunger, Complete, 18mm

(Excluding P223) 3

16 06561 Plunger Complete, 16mm

(P223 Only) 3

16 A 08468 Plunger Base (Excluding P223) 3

16 A 06562 Plunger Base (P223 Only) 3

ITEM PART NO. DESCRIPTION QTY.

16B 08455 Plunger Pipe (Excluding P223) 3

16B 07778 Plunger Pipe (P223 Only) 3

16C 08456 Tension Screw 3

16D 07676 Copper Gasket 3

17 08442 Wrist Pin 3

18 07770 O-Ring 3

19 08356-0010 Oil Seal 3

20 08444 Seal Case (Excluding P223) 3

20 06563 Seal Case (P223 Only) 3

21 08443 O-Ring 3

23 08477 V-Sleeve, Weep

(Excluding P223) 3

23 06315 V-Sleeve (P223 Only) 6

23 A 08087 V-Sleeve, Brown

(Excluding P223) 3

24 07904 Pressure Ring (Excluding P223) 3

24 06290 Pressure Ring (P223 Only) 3

25 08445 Weep Return Ring

(Excluding P223) 3

25 06564 Weep Return Ring (P223 Only) 3

26 06582

+

Valve Casing (Excluding P223)

1/2" Inlet Ports 1

26 06565 Valve Casing (P223 Only) 1

27 07849 Valve Seat 6

28 07491 V alve Plate 6

29 07906 Valve Spring 6

30 07907 Valve Spring Retainer 6

31 07853 O-Ring 6

32 07928 Valve Plug 6

32X 07946 Valve Assembly Complete 6

33 07913 O-Ring 6

34 08316 Hex Head Cap Screw 8

38 13338 Plug, 3/8" BSP 1

38 A 08486 Copper Crush Washer, 3/8 1

39 07109 Plug, 1/2" BSP 1

39 A 07661 Seal 1

+

For pumps w/ 3/8" Inlet, order p/n 08446

9

Specifications

Volume ........................................................................................................ Up to 3.0 GPM

Model P223A

Discharge Pressure (Continuous) ............................................................... Up to 2000 PSI

Discharge Pressure (Intermittent) .............................................................. Up to 2320 PSI*

Inlet Pressure .............................................................................................. 14 to 140 PSI

RPM ........................................................................................................... Up to 3450 RPM

Plunger Diameter ........................................................................................ 16mm

Stroke .......................................................................................................... 6.3mm

Temperature of Pumped Fluids ................................................................... Up to 160

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

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

Shaft Rotation ................................................................................ Top of Pulley Towards Fluid End

Crankshaft Diameter .................................................................................. 24mm

Key Width ................................................................................................... 8 m 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.

Volumetric Efficiency @ 1750 RPM .......................................................... 0.96

Mechanical Efficiency @ 1750 RPM......................................................... 0.85

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.

down at the six o'clock position. Exchange the oil

o

F

P223A HORSEPOWER

REQUIREMENTS

RPM GPM 1000 PSI 2000 PSI 2320 PSI*
1750 1.5 1 .0 2. 1 2. 4
3200 2.8 1 .9 3. 8 4. 5
3450 3.0 2 .1 4. 1 4. 8

*Intermittent duty only

SPECIAL NOTE:

The theoretical gallons per revolution
(gal/rev) is 0.000870
To find specific outputs at various RPM,
use the formula: GPM = 0.000870 x RPM

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:

HP = (GPM X PSI) / 1450

10

pump. Gas

P200A SERIES REPAIR KITS

Plunger Packing Kit

Part # 09164 (Excluding P223)

Item # Qty. Part # Description
23 3 08477 V-Sleeve, weep
23 A 3 08087 V-Sleeve, brown
24 3 07904 Pressure Ring

Plunger Packing Kit

Part #09525 (P223 Only)

Item # Qty. Part # Description
23 6 06315 V-Sleeve
24 3 06920 Pressure Ring

Teflon Plunger Packing Kit

Part # 09164-0020 (Excluding P223)

Item # Qty. Part # Description
23 6 08087-0020 V-Sleeve
24 3 07904 Pressure Ring

Valve Assembly Kit

Part # 09116

Item # Qty. Part # Description
32X 6 07946 Valve Assembly Complete
31 6 07853 O-Ring

Oil Seal Kit

Part # 09144

Item # Qty. Part # Description
19 3 08356-0010 Oil Seal

P200A SERIES TORQUE SPECIFICATIONS

Position Item# Description Torque Amount

16C 08456/07778 Tension Screw, Plunger 220 (in.-lbs.)

32 07928 Valve Plug 33 or 59* (ft.-lbs.)
34 08316 Hex Head Cap Screw, Valve Casing 105 (in.-lbs.)

* For pumps manufactured prior to 5/97, tighten plugs to 33 ft.lbs. Otherwise, tighten to 59 ft.-lbs.

11

PUMP SYSTEM MALFUNCTION

MALFUNCTION

The Pressure and/or
the Delivery Drops

Water in crankcase

Noisy Operation

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

Unloader

High humidity
Worn seals

Worn bearings

Cavitation

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 on inlet of
pump for restrictions
Check for proper operation

Reduce oil change interval
Replace seals

Replace bearings, Refill crankcase
oil with recommended lubricant
Check inlet lines for restrictions
and/or proper sizing

Rough/Pulsating
Operation with
Pressure Drop

Pressure Drop at
Gun

Excessive Leakage

Worn packing
Inlet restriction

Accumulator pressure
Unloader
Cavitation

Restricted discharge plumbing

Worn plungers
Worn packing/seals
Excessive vacuum
Cracked plungers
Inlet pressure too high

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
flow rate of pump

Replace plungers
Adjust or Replace packing seals
Reduce suction vacuum
Replace plungers
Reduce inlet pressure

High Crankcase
Temperature

Wrong Grade of oil
Improper amount of oil in crankcase

12

Giant oil is recommended
Adjust oil level to proper amount

REPAIR INSTRUCTIONS - P200A SERIES

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
(32X).

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 v-sleeve (23)
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!

13

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 - P200A SERIES

9. 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 (16A).
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 (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 P200A series pump

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 (23) over plungers (16)..

3) 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 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). 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.

For maintenance of the gear end of your pump contact Giant Industries or your local distributor.
Phone: [phone]

NOTE: Contact Giant Industries for Service School Information. Phone: [phone]

14

P200A DIMENSIONS (inches)

K6

15

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 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.

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
under warranty 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 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

GIANT INDUSTRIES, INC., 900 N. Westwood Ave., P.O. Box 3187, Toledo, Ohio 43607
PHONE [phone], FAX [phone], www.giantpumps.com
Ó Copyright 2001 Giant Industries, Inc.

03/01 P200A.PM6