Giant P205, P206, P208 User Manual 2

Models P205/206/208

Triplex Ceramic Plunger Pump Operating Instructions/ Repair and Service Manual

Contents:

Installation Instructions: page 2 Pump Specifications: pages 3 -5 Exploded View: page 6 Parts List: page 7 Kits & Torque Specifications:page 7 Repair Instructions: pages 8-9 Trouble Shooting: page 10 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

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 chart on page 3.

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.

Specifications

Model P205

1750 RPM

Ratings (Continuous).................................................................................. 0.5 GPM @ 2000 PSI

Ratings (Intermittent) ................................................................................. 0.5 GPM @ 2500 PSI*

3450 RPM

Ratings (Continuous).................................................................................. 0.9 GPM @ 2000 PSI

Ratings (Intermittent) ................................................................................. 0.9 GPM @ 2500 PSI*

Inlet Pressure .............................................................................................. Up to 90 PSI

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

Plunger Diameter........................................................................................ 12mm

Stroke.......................................................................................................... 3.4mm

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................................................................................................... 8mm

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

Positive inlet pressure required

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:

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.

P205 HORSEPOWER REQUIREMENTS

RPM GPM 1000 PSI 1500 PSI 2000 PSI 2500 PSI*

500 0.13 0.1 0.1 0. 2 0.2 1000 0.26 0.2 0.3 0. 4 0.4 1750 0.46 0.3 0.5 0. 6 0.8 3000 0.80 0.6 0.8 1. 1 1.4 3200 0.83 0.6 0.9 1. 1 1.4 3450 0.90 0.6 0.9 1. 2 1.6

*intermittent duty

HORSEPOWER RA TINGS:

The rating shown are the power

requirements for the

pump. Ga s 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 electricmotor as the power source.

SPECIAL NOTE:

The theoretical gallons per revolution (gal/rev) is 0.0002899.

To compute specific pump horse power requirements, use the following formula:

To find specific outputs at various RPM, use the formula: GPM =0.0002899xRPM

HP = (GPM X PSI) / 1450

Specifications

1750 RPM

Model P206

Ratings (Continuous).................................................................................. 0.8 GPM @ 2000 PSI

Ratings (Intermittent) .................................................................................0.8 GPM @ 2500 PSI*

3450 RPM

Ratings (Continuous).................................................................................. 1.5 GPM @ 2000 PSI

Ratings (Intermittent) .................................................................................1.5 GPM @ 2500 PSI*

Inlet Pressure .............................................................................................. up to 140 PSI

Plunger Diameter........................................................................................ 12mm

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................................................................................... Solid, 24mm

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

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.......................................................... 0.94

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

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

Positive inlet pressure required

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

P206 HORSEPOWER REQUIREMENTS

RPM GPM 1000 PSI 1500 PSI 2000 PSI 2500 PSI*

250 0.11 0.1 0.1 0.2 0.2

500 0.21 0.1 0.2 0.3 0.4 1000 0.43 0.3 0.4 0.6 0.7 1750 0.76 0.5 0.8 1.0 1.3 3000 1.30 0.9 1.3 1.8 2.2 3200 1.40 1.0 1.4 1.9 2.4 3450 1.50 1.0 1.6 2.1 2.6

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

*Intermittent duty only

following formula:

pump. Gas

HP = (GPM X PSI) / 1450

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