Giant P200 Series, P217, P220, P221, P218 Operating Instructions/ Repair And Service Manual

Triplex Ceramic
Plunger Pump
Operating Instructions/

Series

Repair and Service
Manual

P200-18mm versions

For Models:
P217
P218
P219
P220
P221
P227
P230

Updated 09/14

Contents: Page

Installation Instructions: 2

Pump Specications: 3

Exploded View: 4
Parts List: 5
Repair Kits: 6
Pump System Troubleshooting: 7
Recommended Spare Parts List: 8
Pump Mounting Selection Guide: 8

Torque Speciciations: 8

Repair Instructions: 9-10
Dimensions: 11
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 inclina-

tion to ensure optimum lubrication.

2. The inlet to the pump should be sized for
the ow rate of the pump with no unnecessary
restrictions 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
1600 F, it is important to insure a positive head

to the pump to prevent cavitation.

Make sure that suction pulsation is sufciently

dampened - water column resonance must be

avoided.

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 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, connec-

tions, and other system areas. The use of a
dampener with Giant Industries, Inc. pumps
is optional, although recommended by Giant
Industries, Inc. to further reduce system 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 desig-

nated by the arrows on the pump crankcase.
Reverse rotation may be safely achieved by
following a few guidelines available upon
request from Giant Industries, Inc. Required

horsepower for system operation can be ob-

tained 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. Cavi­tation 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.

Important! If there is a danger of frost, the

water in the pump and in the pump ttings
(particularly the unloader valve) must be emp­tied. The second discharge port can be used

and the pump run “dry” for 1-2 minutes for this

purpose.

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.

3. Acids, alkalines, or abrasive uids cannot
be pumped unless approval in writing is ob­tained before operation from Giant Industries,
Inc.

Use Giant 20W-50 oil (p/n 01153)

4. Run the pump dry approximately 10 sec-

Crankcase oil should be changed after the

rst 50 hours of operation, then at regular inter-

onds to drain the water before exposure to

freezing temperatures.
vals of 500 hours or less depending on operat­ing conditions.

5. If there is danger of frost, the

water in the pump and in the pump ttings (par-

2. Pump operation must not exceed rated
pressure, volume, or RPM. A pressure relief
device must be installed in the discharge of the
system.

ticularly the unloader valve) must be emptied.

The second discharge port can also be used

and the pump run “dry” for 1-2 minutes for this

purpose.

2

Pump Specications

Max.

Max.

Flow

Flow

Model GPM l/min PSI bar RPM PSI bar in mm in mm BHP kW

P230 1.1 4.2 2000/2500 140/172 1750 145 10 0.71 18 0.13 3.4 1.5/1.9 1.1/1.4

P217 1.8 6.8 2000/2500 140/172 1750 145 10 0.71 18 0.22 5.5 2.5/3.1 1.9/2.3

P230 2.0 7.8 2000/2500 140/172 3450* 145 10 0.71 18 0.13 3.4 2.8/3.5 2.1/2.6

P227 2.1 8.0 2000/2500 140/172 1750 145 10 0.71 18 0.25 6.3 2.9/3.6 2.2/2.7

P221 2.3 8.9 2000/2500 140/172 1750 145 10 0.71 18 0.28 7.0 3.2/4.0 2.4/3.0

P217 3.3 12.5 2000/2500 140/172 3450* 145 10 0.71 18 0.22 5.5 4.6/5.7 3.4/4.3

P218 3.4 12.9 2000/2500 140/172 1750 145 10 0.71 18 0.39 10.0 4.7/5.9 3.5/4.4

P227 3.8 14.4 2000/2500 140/172 3450* 145 10 0.71 18 0.25 6.3 5.2/6.6 3.9/4.9

P219 4.2 15.9 2000/2500 140/172 1750 145 10 0.71 18 0.49 12.4 5.8/7.2 4.3/5.4

P221 4.2 15.9 2000/2500 140/172 3450* 145 10 0.71 18 0.28 7.0 5.8/7.2 4.3/5.4

P220 4.7 17.8 2000/2500 140/172 1750 145 10 0.71 18 0.56 14.1 6.5/8.1 4.8/6.0

*

Positive inlet pressure required- Make sure that suction pulsation is sufciently dampened-water column resonance must be avoided.

Common Specications U.S. Metric

Max. Temperature of Pumped Fluids ..................... 160o F** ................................................................71o C**

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

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

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

Crankshaft Diameter..............................................0.98” ...................................................................... 24 mm

Key Width .............................................................. 0.31” ........................................................................ 8 mm

Shaft Mounting .....................................................................................................Right Side Facing Manifold

Weight ...................................................................11.7 lbs. ..................................................................5.3 Kg

Crankcase Oil Capacity .........................................7.5 .oz. ............................................................0.22 Liter

Extended Crankcase Oil Capacity ......................... 9.0 .oz. ............................................................ 0.27 Liter

Volumetric Efciency @ 1750 RPM ..........................................................................................................0.94

Volumetric Efciency @ 3450 RPM ..........................................................................................................0.87

Mechanical Efciency @ 3450 RPM ........................................................................................................ 0.86

Nominal/

Intermittent

Pressure

Nominal/

Intermittent

Pressure

**For P200-HK pump the rating is 195o F (90o C) . Max. Pressure = 2000 PSI (140 bar)

Max.

Speed

Max.

Inlet

Pressure

Max.

Inlet

Pressure

Plunger

Diameter

Plunger

Diameter

Stroke Stroke Power

Req’d

Power

Req’d

Consult the factory for special requirements that must be met if the
pump is to operate beyond one or more of the limits specied 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 ll and the oil drain plugs, also. Refer to the repair instructions as necessary for the
proper assembly sequence.

Horsepower Ratings:

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

3

Exploded View

P217/P218/P219/P220/P221/P227/P230

4

Spare Parts

P217/P218/P219/P220/P221/P227/P230

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 01176-2 Spring Washer 4

7 08303 Bearing Cover I 2

8 08490 Sight Glass 1

9 08492 O-Ring for Sight Glass 1

10 07225 Screw with Lock Washer 8

11 01166 Radial Shaft Seal 1

12A 08020 Ball Bearing 1

12B 01020 Ball Bearing 1

13 08465 Crankshaft (P217) 1

13 08440 Crankshaft (P218) 1

13 08466 Crankshaft (P219) 1

13 08467 Crankshaft (P220) 1

13 12258 Crankshaft (P221) 1

13 06547 Crankshaft (P227) 1

13 06694 Crankshaft (P230) 1

14 06207 Woodruff Key 1

15 08333 Connecting Rod 3

16 08469 Plunger, Complete, 18mm 3

ITEM PART NO. DESCRIPTION QTY.

16A 08468 Plunger Base 3

16B 08455 Plunger Pipe 3

16C 08456 Tension Screw 3

16D 07676 Copper Gasket 3

17 08442 Wrist Pin 3

18 07770 O-Ring 3

19 08356 Oil Seal 3

20 08444 Seal Case 3

21 08443 O-Ring 3

23 08477 V-Sleeve, Weep 3

23A 08087 V-Sleeve, Brown 3

24 07904 Pressure Ring 3

25 08445 Weep Return Ring 3

26 06582+ Valve Casing 1/2” Inlet Ports 1

27 07849 Valve Seat 6

28 07491 Valve Plate 6

29 07906 Valve Spring 6

30 07907 Valve Spring Retainer 6

31 07853 O-Ring 6

32 07928 Valve Plug 6

32X 07946A Valve Assembly Complete 6

33 07913 O-Ring 6

34 08316 Hex Head Cap Screw 8

38 13338 Plug, 3/8” BSP 1

38A 08486 Copper Crush Washer, 3/8” 1

39 07109 Plug, 1/2” BSP 1

39A 07661 Seal 1

5

Repair Kits

P217/P218/P219/P220/P221/P227/P230

Plunger Packing Kit

Part # 09164

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

Valve Assembly Kit

Part # 09116

Item # Part # Description Qty.
32X 07946A Valve Assembly Complete 6
31 07853 O-Ring 6
33 07913 O-Ring 6

Oil Seal Kit

Part # 09144

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

Optional Kits

Teon Plunger Packing Kit

Part # 09164-0021

Item # Part # Description Qty.
18 07770-0001 O-Ring, Viton 3
21 08443-0001 O-Ring, Viton 3
23/23A 08087-0020 Weep Seal, Teon 6
24 07904 Pressure Ring 3
31 07853-0001 O-Ring, Viton 6
33 07913-0001 O-Ring, Viton 6

Viton Seal Kit

# 09164-0011

Item Part # Description Qty.
18 07770-0001 O-Ring, Viton 3
21 08443-0001 O-Ring, Viton 3
23 08087-0010 V-Sleeve 6
24 07904 Pressure Ring 3
31 07853-0001 O-Ring, Viton 6
33 07913-0001 O-Ring, Viton 6

High Temperature Seal Kit

# 09599

Item Part # Description Qty.
23/23A 08477-0030 High-Temp Seal 6

24 07904 Pressure Ring 6+

+ Kit contains six (6) pressure rings. Only three (3)
are required for the P200 Series Pumps.

6

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, Rell 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
Rated, Pressure ow rate of pump
Drop at gun

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

7

Preventative Maintenance Check List & Recommended Spare

Check Daily Weekly 50 Hrs.

Every

500 Hrs

Every

1500 Hrs

Every

3000 Hrs

Oil Level/Quality X
Oil Leaks X
Water Leaks X
Belts, Puelly X
Plumbing X

Oil Change
(1 gallon) p/n 01154

X X

Plunger Seal Kit

(1 kit/pump)

X

Oil Seal Kit
(1 kit/pump)

X
Inlet and Valve Repair
Kit (1 kit/pump)

X

Preventative Maintenance Check List & Recommended Spare Parts List

Recommended Spare Parts

Parts List

(1 quart) p/n 01153

Valve Assembly

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=5.75”x W=1.00”x h=2.50”)
01161 - Plated Steel Channel Rails
(L=5.75”x W=1.00”x H=2.50”)

Torque Specications

Position Item# Description Torque Amount

16C 08456 Tension Screw, Plunger 200 in.-lbs. (22.5 Nm)
32 07928 Valve Plug 55 ft.-lbs. (75 Nm)
34 08316 Hex Head Cap Screw, Valve Casing 106 in.-lbs. (12 Nm)

8

REPAIR INSTRUCTIONS - P217/P218/P219/P220/P221/P227/P230 PUMPS

NOTE: Always take time to lubricate all metal and nonmetal parts with a light lm of oil before reassembly.
This step will ensure proper t, 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 neces-

sary. Apply one drop of
Loctite 243 to the valve
plugs (32) and tighten to
55 ft.-lbs. (75 Nm)

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 (23A) from the
seal case (20). Inspect
all parts, including o-ring
(21) for wear and re-

place as necessary

8. Check surfaces of
plunger (16). A dam-

aged surface will cause
accelerated wear on

the seals. Deposits of

any kind must be care-

fully removed from the
plunger surface. A dam-

aged plunger must be
replaced!

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.

9

REPAIR INSTRUCTIONS - P217/P218/P219/P220/P221/P227/P230 PUMPS

10. 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 200 in.-lbs. (22.5 Nm)

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 P217/P218/P219/P220/P221/P227/P230
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). As-

semble 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
106 inch-pounds (12 Nm) 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 55 ft.-lbs. (75
Nm).

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

10

Dimensions - Inches (mm)

P217/P218/P219/P220/P221/P227/P230

11

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 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 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 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., P.O. Box 3187, Toledo, Ohio 43607
Phone: [phone] FAX [phone], www.giantpumps.com
 Copyright 2014 Giant Industries, Inc.

10/14 P200-18mm.indd