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
1200 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.
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.
For P218A, P219A and P220A, use
Giant Industries, Inc. oil (part # 01060) or
the equivalent Kendall Turbo GT1 (20w-50)
oil may be used. For P217A use Giant Oil
(part #01150) or Mobil 1 (15W-50).
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
Volume ................................................................................................... Up to 3.4 GPM
Discharge Pressure ................................................................................ Up to 2000 PSI
Inlet Pressure ......................................................................................... Up to 90 PSI
RPM ...................................................................................................... Up to 3450 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 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.
The rating shown are 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
factorbe specified when
selecting an electric motor as the
power source.To compute
specific pump horse power requirements, use thefollowing formula:
HP = (GPM X PSI) / 1450
Specifications
Volume ................................................................................................... Up to 3.4 GPM
Discharge Pressure ................................................................................ Up to 2000 PSI
Inlet Pressure ......................................................................................... Up to 90 PSI
RPM ...................................................................................................... Up to 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 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.
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
HORSEPOWER RATINGS:
The rating shown are the power
requirements for the pump. Gas
engine power outputs must be
approximately twice the pump
power requirements shown above.
We recommend a 1.15 service
factorbe specified when
selecting an electric motor as the
power source.To compute
specific pump horse power requirements, use thefollowing formula:
HP = (GPM X PSI) / 1450
Specifications
Volume ....................................................................................................... Up to 4.2 GPM
Discharge Pressure ..................................................................................... Up to 2000 PSI
Inlet Pressure ............................................................................................. Up to 90 PSI
RPM .......................................................................................................... Up to 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 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.
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 pump. Gas
engine power outputs must be
approximately twice the pump
power requirements shown above.
We recommend a 1.15 service
factorbe specified when
selecting an electric motor as the
power source.To compute
specific pump horse power requirements, use thefollowing formula:
HP = (GPM X PSI) / 1450
Specifications
Model P220A-3100/5100
Volume ....................................................................................................... Up to 4.7GPM
Discharge Pressure ..................................................................................... Up to 2000 PSI
Inlet Pressure ............................................................................................. Up to 90 PSI
RPM .......................................................................................................... Up to 1725 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 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.
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.
Disassembly sequence of fluid end of P200A-3100/5100 series pump
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.
2)Using a needle nose pliers, remove the inlet and discharge valve assemblies (32X). By inserting a small
screw driver between the valve seat (27) and the valve spring retainer (30), the valve assembly can be
separated. Remove the o-ring (31). Inspect all parts for wear and replace as necessary.
3)Next, use a 5mm allen wrench to remove the 8 socket head cap screws (34). Carefully slide the valve
casing (26) out over the plungers. 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.
4)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!
5)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 inchpounds.
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.
5)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. If the oil seals are not to be replaced,
proceed to the back end disassembly sequence and carefully pry the seals loose after the plungers have
been removed from the crankcase. The seals should not be reinstalled until after step #2 of the "Reassembly Sequence".
REPAIR INSTRUCTION - P200A-3100/5100 SERIES
Disassembly sequence of the back end of the P200A-3100/5100 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
connecting 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 (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 find it necessary to service the plunger assembly (#16) you can do so by removing the tension
screw (#16D). Inspect all parts and replace as necessary.
Reassembly sequence of the of the P200A-3100/5100 series pump
1)Reassemble plunger (16) and the connecting rod (15) with wrist pin (17). Place assemblies in crankcase
(1). Install crankshaft through connecting 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 v-sleeve (23) over plungers (16)..
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.
6)Replace the six o-rings (31) and the six valve assemblies (32X). 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 9.5 ounces (6.5 ounces for P217A) of oil.
NOTE: Contact Giant Industries for Service School Information. Phone: (419)-531-4600
P200A-3100/5100 DIMENSIONS (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 car wash applications, the discharge manifolds
willnever fail, period. If they ever fail, we will replace them free of charge. Our other
pumpparts, used in portable pressure washers and in car wash applications, are
warrantedfor 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 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 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.