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P217A-5100

Giant P200A-5100 Series, P218A-5100, P219A-5100, P217A-5100, P221A-5100 Operating Instructions/ Repair And Service Manual

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P200A-5100
SERIES PUMPS
18mm Versions
316 Stainless Steel Models:
P217A-5100, P218A-5100, P219A-5100, P220A-5100, P221A-5100, P227A-5100, P230A-5100
Plunger Pump
Operating Instructions/
Repair and Service Manual
Updated 10/13
Contents:
Installation Instructions: page 2
Pump Specications: pages 3-9
Exploded View: page 10 Parts List / Kits: page 11
Repair Instructions: pages 12-13 Torque Specications: page 13
Trouble Shooting Guide and Recommended Spare Parts List: page 14 Dimensions: page 15 Pump mounting selection Guide: 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 at on a base
to a maximum of a 15 degree angle of inclination
o
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 86 F
o
(30
C), it is important to insure a positive head
o
to the pump to prevent cavitation.
3. The discharge plumbing from the pump should be properly sized to the ow rate to pre-
vent 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 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 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 3-9.
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.
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)
Crankcase oil should be changed after the
rst 50 hours of operation, then at regular inter-
vals 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 uids 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.
2
Specications
RPM GPM 800 PSI 1200 PSI 1500 PSI 1700 PSI 2000 PSI 1450 1.5 0.8 1.2 1.6 1.8 2.1 1750 1.8 1.0 1.5 1.9 2.1 2.5
3000 3.2 1.8 2.6 3.3 3.8 4.4 3200 3.4 1.9 2.8 3.5 4.0 4.7 3450 3.6 2.0 3.0 3.7 4.2 5.0
P217A-5100 HORSEPOWER REQUIREMENTS
Model P217A-5100
U.S. (Metric) 1750 RPM *
Ratings
3450 RPM *
Ratings Plunger Diameter Stroke
Temperature of Pumped Fluids..................Up to 86
Inlet Ports Discharge Ports Shaft Rotation Crankshaft Diameter Key Width
Shaft Mounting
Weight Crankcase Oil Capacity
Volumetric Efciency @ 1750 RPM Mechanical Efciency @ 1750 RPM
*15 PSI inlet pressure required
......................................................1.85 GPM @ 2000 PSI .....(7.0 LPM @ 140 bar)
......................................................3.6 GPM @ 2000 PSI .......(13.8 LPM @ 140 bar)
......................................0.71” .................................18mm
.......................................................0.22” ................................. 5.5mm
...........................................................................................(2) 1/2” BSP
.................................................................................. (2) 3/8” BSP
.....................................................................................Top of Pulley Towards Fluid End
.................................0.94” .................................24mm
.................................................0.31” ................................. 8mm
....................................................................................Either Side
.......................................................13 lbs. 4oz. ...................... (6.0 kg)
............................8.1 .oz. ...........................(0.24 liters)
....................................................0.90
..................................................0.88
o
F ......................(30o C)
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.
PULLEY INFORMATION
Pulley selection and pump speed are based
on a 1725 RPM motor and “B” section belts. When selecting desired GPM, allow for a ±5% tolerance on pumps output due to vari­ations in pulleys, belts and motors among
manufacturers.
1. Select GPM required, then select appro-
priate motor and pump pulley from the same line.
2. The desired pressure is achieved by selecting the correct nozzle size that
corresponds with the pump GPM.
HORSEPOWER INFORMATION
Horsepower ratings shown are the power re­quirements for the pump. Gas engine power outputs must be approximately twice the pump power requirements shown above. We recommend that a 1.15 service factor
be specied when selecting an electric motor as the power source. To compute specic pump horsepower requirements, use the
following formula:
GPM X PSI
1450
=HP
3
Specications
RPM GPM 800 PSI 1200 PSI 1500 PSI 1700 PSI 2000 PSI 1150 2.2 1.2 1.8 2.3 2.6 3.0 1450 2.8 1.5 2.3 2.9 3.3 3.9 1750 3.4 1.9 2.8 3.5 4.0 4.7
P218A-5100 HORSEPOWER REQUIREMENTS
Model P218A-5100
U.S. (Metric)
Volume .......................................................3.4 GPM ...........................(12.8 LPM)
Discharge Pressure Inlet Pressure
.......................................................................................................Up to 1750 RPM
RPM
Plunger Diameter Stroke Temperature of Pumped Fluids Inlet Ports Discharge Ports Shaft Rotation Crankshaft Diameter Key Width
Shaft Mounting
Weight Crankcase Oil Capacity
Volumetric Efciency @ 1750 RPM Mechanical Efciency @ 1750 RPM
.........................................................0.39” ..................................10.0mm
.............................................................................................(2) 1/2” BSP
...................................................0.31” ..................................8mm
.........................................................13 lbs. 4 oz. ......................(6.0 kg)
....................................2000 PSI ..........................(140 bar)
.............................................90 PSI ..............................(6.2 bar)
........................................0.71” ..................................18mm
o
..................Up to 86
.....................................................................................(2) 3/8” BSP
........................................................................................Top of Pulley Towards Fluid End
...................................0.94” ..................................24mm
......................................................................................Either Side
..............................8.1 .oz. ............................(0.24 liters)
.......................................................0.96
.....................................................0.85
F ........................(30o C)
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.
PULLEY INFORMATION
Pulley selection and pump speed are based on
a 1725 RPM motor and “B” section belts. When selecting desired GPM, allow for a ±5% tolerance on pumps output due to variations in pulleys, belts
and motors among manufacturers.
1. Select GPM required, then select appropriate
motor and pump pulley from the same line.
2. The desired pressure is achieved by selecting the correct nozzle size that corresponds with the
pump GPM.
HORSEPOWER INFORMATION
Horsepower ratings shown are the power re­quirements for the pump. Gas engine power outputs must be approximately twice the pump power requirements shown above. We recommend that a 1.15 service factor
be specied when selecting an electric motor as the power source. To compute specic pump horsepower requirements, use the
following formula:
GPM X PSI
1450
= HP
4
Specications
RPM GPM 800 PSI 1200 PSI 1500 PSI 1700 PSI 2000 PSI 1150 2.8 1.5 2.3 2.9 3.3 3.9 1450 3.5 1.9 2.9 3.6 4.1 4.8 1750 4.2 2.3 3.5 4.3 4.9 5.8
P219A-5100 HORSEPOWER REQUIREMENTS
Model P219A-5100
U.S. (Metric)
Volume ....................................................4.2 GPM .................. (15.9 LPM)
Discharge Pressure Inlet Pressure
........................................................................................... Up to 1750 RPM
RPM
Plunger Diameter Stroke
......................................................0.49” ......................... 12.4mm
Temperature of Pumped Fluids Inlet Ports
.................................................................................. (2) 1/2” BSP
Discharge Ports Shaft Rotation Crankshaft Diameter Key Width
................................................0.31” ......................... 8mm
Shaft Mounting
Weight
......................................................13 lbs. 4 oz. ............ (6.0 kg)
Crankcase Oil Capacity
Volumetric Efciency @ 1750 RPM Mechanical Efciency @ 1750 RPM
.................................2000 PSI ................. (140 bar)
...........................................90 PSI ..................... (6.2 bar)
.....................................0.71” ......................... 18mm
................Up to 86
o
F ............... (30
o
C)
......................................................................... (2) 3/8” BSP
............................................................................Top of Pulley Towards Fluid End
................................0.94” ......................... 24mm
........................................................................... Either Side
...........................8.1 .oz. ...................(0.24 liters)
...........................................0.96
......................................... 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 specied above.
PULLEY INFORMATION
Pulley selection and pump speed are based on
a 1725 RPM motor and “B” section belts. When selecting desired GPM, allow for a ±5% tolerance on pumps output due to variations in pulleys, belts
and motors among manufacturers.
1. Select GPM required, then select appropriate
motor and pump pulley from the same line.
2. The desired pressure is achieved by selecting the correct nozzle size that corresponds with the
pump GPM.
HORSEPOWER INFORMATION
Horsepower ratings shown are the power re­quirements for the pump. Gas engine power outputs must be approximately twice the pump power requirements shown above. We recommend that a 1.15 service factor
be specied when selecting an electric motor as the power source. To compute specic pump horsepower requirements, use the
following formula:
GPM X PSI
1450
= HP
5
Specications
RPM GPM 800 PSI 1200 PSI 1500 PSI 1700 PSI 2000 PSI 1150 3.1 1.7 2.6 3.2 3.6 4.3 1450 3.9 2.2 3.2 4.0 4.6 5.4 1750 4.7 2.6 3.9 4.9 5.5 6.5
P220A-5100 HORSEPOWER REQUIREMENTS
Model P220A-5100
U.S. (Metric)
Volume .......................................................4.7GPM* .................. (17.6 LPM)*
Discharge Pressure ...................................2000 PSI .................. (140 bar)
Inlet Pressure
.............................................................................................. Up to 1750 RPM
RPM
Plunger Diameter Stroke Temperature of Pumped Fluids Inlet Ports Discharge Ports Shaft Rotation Crankshaft Diameter Key Width
Shaft Mounting
Weight Crankcase Oil Capacity
Volumetric Efciency @ 1750 RPM Mechanical Efciency @ 1750 RPM
........................................................0.56” ..........................14.1mm
........................................................13 lbs. 4oz. .............. (6.0 kg)
*Positive inlet pressure required
.............................................90 PSI ...................... (6.2 bar)
.......................................0.71” .......................... 18mm
o
..................Up to 86
..................................................................................... (2) 1/2” BSP
............................................................................ (2) 3/8” BSP
...............................................................................Top of Pulley Towards Fluid End
..................................0.94” .......................... 24mm
..................................................0.31” ..........................8mm
.............................................................................. Either Side
.............................8.1 .oz. ................... (0.24 liters)
..............................................0.96
............................................ 0.85
F ............... (30o C)
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.
PULLEY INFORMATION
Pulley selection and pump speed are based on
a 1725 RPM motor and “B” section belts. When selecting desired GPM, allow for a ±5% tolerance on pumps output due to variations in pulleys, belts
and motors among manufacturers.
1. Select GPM required, then select appropriate
motor and pump pulley from the same line.
2. The desired pressure is achieved by selecting the correct nozzle size that corresponds with the
pump GPM.
HORSEPOWER INFORMATION
Horsepower ratings shown are the power re­quirements for the pump. Gas engine power outputs must be approximately twice the pump power requirements shown above. We recommend that a 1.15 service factor
be specied when selecting an electric motor as the power source. To compute specic pump horsepower requirements, use the
following formula:
GPM X PSI
1450
= HP
6
Specications
RPM GPM 1000 PSI 1500 PSI 2000 PSI 1450 2.0 1.4 2.1 2.8 1750 2.3 1.7 2.5 3.3
3000 4.1 2.8 4.2 5.7 3200 4.3 3.0 4.4 5.9 3450 4.7 3.2 4.9 6.5
P221-5100 HORSEPOWER
REQUIREMENTS
Model P221A-5100
U.S. (Metric) 1750 RPM *
Ratings
.....................................................2.34 GPM @ 2000 PSI ......(8.9 LPM @ 140 bar)
3450 RPM *
Ratings Inlet Pressure
RPM
Plunger Diameter Stroke Temperature of Pumped Fluids Inlet Ports Discharge Ports Shaft Rotation Crankshaft Diameter Key Width
Shaft Mounting
Weight Crankcase Oil Capacity
Volumetric Efciency @ 1750 RPM Volumetric Efciency @ 3450 RPM Mechanical Efciency @ 1750 RPM
.....................................................4.6 GPM @ 2000 PSI ........(17.6 LPM @ 140 bar)
...........................................-4.35 to 145 PSI ................(-0.3 to 10 bar)
....................................................................................................Up to 3450 RPM
.....................................0.71” ..................................18mm
......................................................0.28” ..................................7.0mm
................Up to 86
o
F .........................(30
o
C)
...........................................................................................(2) 1/2” BSP
..................................................................................(2) 3/8” BSP
.....................................................................................Top of Pulley Towards Fluid End
...........................................................................24mm
...........................................................................................8mm
....................................................................................Right Side Facing Manifold
......................................................13 lbs. 4oz. ........................(6.0 kg)
...........................8.1 .oz. .............................(0.24 liter)
....................................................0.95
....................................................0.87
..................................................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 specied above.
PULLEY INFORMATION
Pulley selection and pump speed are based on
a 1725 RPM motor and “B” section belts. When selecting desired GPM, allow for a ±5% tolerance on pumps output due to variations in pulleys, belts
and motors among manufacturers.
1. Select GPM required, then select appropriate
motor and pump pulley from the same line.
2. The desired pressure is achieved by select­ing the correct nozzle size that corresponds with
the pump GPM.
P221A-5100
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 factor be
specied when selecting an electric motor as the power source. To compute specic pump horsepower requirements, use the following
formula: GPM X PSI = HP 1450
7
Specications
RPM GPM 1000 PSI 1500 PSI 2000 PSI 1450 1.7 1.2 1.8 2.4 1750 2.1 1.4 2.2 2.9
3000 3.3 2.3 3.4 4.6 3200 3.5 2.4 3.6 4.9 3450 3.8 2.6 3.9 5.2
P227-5100 HORSEPOWER
REQUIREMENTS
Model P227A-5100
U.S. (Metric) 1750 RPM *
Ratings
3450 RPM *
Ratings Inlet Pressure
RPM
Plunger Diameter Stroke Temperature of Pumped Fluids Inlet Ports Discharge Ports Shaft Rotation Crankshaft Diameter Key Width
Shaft Mounting
Weight Crankcase Oil Capacity
Volumetric Efciency @ 1750 RPM Volumetric Efciency @ 3450 RPM Mechanical Efciency @ 3450 RPM
.......................................................2.1 GPM @ 2000 PSI .......(8.0 LPM @ 140 bar)
.......................................................3.8 GPM @ 2000 PSI .......(14.4 LPM @ 140 bar)
.............................................-4.35 to 145 PSI ................(-0.3 to 10 bar)
......................................................................................................Up to 3450 RPM
.......................................0.71” ..................................18mm
........................................................0.25” ..................................6.3mm
..................Up to 86
o
F ........................(30
o
C)
.............................................................................................(2) 1/2” BSP
....................................................................................(2) 3/8” BSP
.......................................................................................Top of Pulley Towards Fluid End
.............................................................................24mm
.............................................................................................8mm
......................................................................................Right Side Facing Manifold
........................................................13 lbs. 4 oz. .......................(6.0 kg)
.............................8.1 .oz. ............................(0.24 liter)
......................................................0.95
......................................................0.87
....................................................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 specied above.
PULLEY INFORMATION
Pulley selection and pump speed are based on
a 1725 RPM motor and “B” section belts. When selecting desired GPM, allow for a ±5% tolerance on pumps output due to variations in pulleys, belts
and motors among manufacturers.
1. Select GPM required, then select appropriate
motor and pump pulley from the same line.
2. The desired pressure is achieved by selecting the correct nozzle size that corresponds with the
pump GPM.
P227A-5100
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 factor be speci-
ed when selecting an electric motor as the
power source. To compute
specic pump horsepower requirements, use
the following formula: GPM X PSI = HP 1450
8
Specications
RPM GPM 1000 PSI 1500 PSI 2000 PSI 1450 0.9 0.6 0.9 1.2 1750 1.1 0.8 1.1 1.5
3000 1.9 3.6 2.0 2.6 3200 2.0 3.8 2.1 2.8 3450 2.1 4.0 2.2 2.9
P230-5100 HORSEPOWER
REQUIREMENTS
Model P230A-5100
U.S. (Metric) 1750 RPM *
Ratings
......................................................1.1 GPM @ 2000 PSI .....(4.1 LPM @ 140 bar)
3450 RPM *
Ratings Inlet Pressure
RPM
Plunger Diameter Stroke Temperature of Pumped Fluids Inlet Ports Discharge Ports Shaft Rotation Crankshaft Diameter Key Width
Shaft Mounting
Weight Crankcase Oil Capacity
Volumetric Efciency @ 1750 RPM Volumetric Efciency @ 3450 RPM Mechanical Efciency @ 3450 RPM
......................................................2.1 GPM @ 2000 PSI .....(8.1 LPM @ 140 bar)
............................................14 to 145 PSI ..................(1 to 10 bar)
...................................................................................................Up to 3450 RPM
...................................... 0.71” ................................18mm
.......................................................0.13” ................................3.4mm
.................Up to 86
o
F ......................(30
o
C)
..........................................................................................(2) 1/2” BSP
.................................................................................(2) 3/8” BSP
......................................................................................Top of Pulley Towards Fluid End
..........................................................................24mm
..........................................................................................8mm
...................................................................................Right Side Facing Manifold
....................................................... 13 lbs. 4 oz. ....................(6.0 kg)
............................ 8.1 .oz. ..........................(0.24 liter)
...................................................0.94
...................................................0.87
.................................................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 specied above.
PULLEY INFORMATION
Pulley selection and pump speed are based on a 1725
RPM motor and “B” section belts. When selecting desired GPM, allow for a ±5% tolerance on pumps output due to variations in pulleys, belts and motors
among manufacturers.
1. Select GPM required, then select appropriate
motor and pump pulley from the same line.
2. The desired pressure is achieved by selecting the correct nozzle size that corresponds with the
pump GPM.
P230A-5100
HORSEPOWER RATINGS:
The rating shown are the power require-
ments for the pump. Gas engine power outputs must be approximately twice the pump power requirements shown above.
We recommend a 1.15 service factor be
specied when selecting an electric motor as the power source. To compute specic pump horsepower requirements, use the
following formula:
GPM X PSI = HP 1450
9
Exploded View - P200A-5100 Series
26A
26A
10
P200A-5100 SERIES PARTS LIST
ITEM PART NO. DESCRIPTION QTY.
1 08300A Crankcase, Anodized 1 2 08301 Dipstick, Except P217-5100 1 2 08480 Dipstick, P217-5100 Only 1 3 08302A Crankcase Cover, Anodized 1 3A 07190-0100 Drain Plug & Gasket 1 4 08005 O-Ring 1 5 08185-0100 Oil Drain Plug with seal 1 6 07188-0100 Screw, 316 S.S. 4 6A 07223-0100 Spring Washer, 316 S.S. 4 7 08303 Bearing Cover 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-5100) 1 13 08440 Crankshaft (P218A-5100) 1 13 08466 Crankshaft (P219A-5100) 1 13 08467 Crankshaft (P220A-5100) 1 13 12258 Crankshaft (P221A-5100) 1 13 06547 Crankshaft (P227A-5100) 1 13 06694 Crankshaft (P230A-5100) 1
14 06207 Fitting Key 1
15 08333 Connecting Rod 3 16 08469-0100 Plunger Assembly, Except P230-5100 3 16A 08468-0100 Plunger Base, 316 S.S. 3 16B 08455 Plunger 3 16C 08456-0100 Tension Screw, 316 S.S. 3 16D 07204-0100 Crush Washer, 316 S.S. 3 16E 07203 Support Ring 3
ITEM PART NO. DESCRIPTION QTY.
16F 07023 O-Ring 3 17 08442 Wrist Pin 3 19 08356-0010 Oil Seal 3 20 08444A-0100 Seal Retainer, 316 S.S. 3 21 08443 O-Ring (-5100) 3 21 12260-0001 O-Ring, Viton (-5111/-5121) 3 23 08477 Grooved Seal (P218/P219/P220-5100) 3 23 08087-0010 Grooved Seal, Viton (P218/P219/P220-5111) 6 23 06704 Grooved Seal (P217/P221/P227/P230-5100) 3 23 08087-0020 Grooved Seal, Teon (-5121) 6 23A 08087 Grooved Seal Ring, Brown (-5100) 3 23B 06163 Drip Shield 3 24 07904 Pressure Ring 3 25 08445-0100 Weep Return Ring, 316 S.S. 3
26 06582-5000 Valve Casing 1
26A 07946-0100 Valve Assembly 6 27 07849-0100 Valve Seat 6 28 06809 Valve Plate 6 29 07906-0100 Valve Spring 6 30 07907 Valve Spring Retainer 6 30A 06824 Spacer Ring, P230-5100 Only 3 31 07853 O-Ring (-5100) 6 31 07853-0001 O-Ring (-5111/-5121) 6
32 07928-0100 Plug 6
33 07913 O-Ring (-5100) 6 33 07913-0001 O-Ring (-5111/-5121) 6 34 08316-0100 Hex Head Cap Screw 8
36 12138 Plug, 3/8” 1
36A 07109-0400 Plug, 1/2” 1
P200A-5100 SERIES REPAIR KITS
Plunger Packing Kits Part#09602 - P218A/P219A/P220A-5100
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
Part#09602-0011-P218A/P219A/220A-5111
Item Part# Description Qty.
23 08087-0010 Grooved Seal, Viton 6 23B 06163 Drip Shield 3 24 07904 Pressure Ring 3
Part#09602-0021-P218A/P219A/P220A-5121
Item Part# Description Qty.
23 08087-0020 Grooved Seal, Teon 6 23B 06163 Drip Shield 3 24 07904 Pressure Ring 3
Part#09756-P217A/P221A/P227A/230A-5100
Item Part# Description Qty.
23 06704 Grooved Seal 3 23A 08087 Grooved Seal Ring 3 23B 06163 Drip Shield 3 24 07904 Pressure Ring 3
Valve Assembly Kit Part # 09139 - For -5100 Series
Item Part # Description Qty.
27 07849-0100 Valve Seat 6 28 06809 Valve Plate 6 29 07906-0100 Valve Spring 6 30 07907 Valve Retainer 6 31 07853 O-Ring 6
33 07913 O-Ring 6
Valve Assembly Kit Part # 09139-0011 - For -5111/-5121
Item Part # Description Qty.
27 07849-0100 Valve Seat 6 28 06809 Valve Plate 6 29 07906-0100 Valve Spring 6 30 07907 Valve Retainer 6 31 07853-0001 O-Ring 6 33 07913-0001 O-Ring 6
Oil Seal Kit Part# 09144
Item Part # Description Qty.
19 08356-0010 Oil Seal 3
11
REPAIR INSTRUCTION - P200A-5100 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 dis­charge valve assemblies
(26A), for P230-5100 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) and drip shield (23B)
from the seal case (20).
Inspect all parts, including 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. Deposits of any kind must be carefully removed from the plunger surface. A damaged plunger must be replaced!
12
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 INSTRUCTION - P200A-5100 SERIES
Disassembly sequence of the back end of the P200A-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 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 prior to replacing it. NOTE: Place side with line in the middle on the ceramic surface and use a hand press to cursh the washer prior to installing the tension screw. Inspect all
parts and replace as necessary.
Reassembly sequence of the P200A-5100 series pump
1) Reassemble plunger asembly (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 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 crank-
case. 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 plung-
ers 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 (30A), P230-5100 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.
5
3
1
8
7
2
4
6
P200A-5100 SERIES TORQUE SPECIFICATIONS
Position Item# Description Torque Amount (ft.-lbs) Nm
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.) 11.9 Nm
13
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
Pressure Drop at Gun Restricted discharge plumbing Re-size discharge plumbing to ow rate of pump
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
Preventative Maintenance Check-List & Recommended Spare Parts List
Check Daily Weekly 50hrs Every Every Every 500 hrs 1500 hrs 3000 hrs
Oil Level/Quality X Oil Leaks X Water Leaks X Belts, Pulley X Plumbing X
Recommended Spare Parts
Oil Change X X
Seal Spare Parts (1 kit/pump) X
(See page 11 for kit list) Oil Seal Kit (1 kit/pump) X
(See page 11 for kit lit)
Valve Spare Parts (1 kit/pump) X
(See page 11 for kit list)
14
P200A-5100 DIMENSIONS - INCHES (mm)
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”)
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 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 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 consid-
eration. 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 IN-
DIRECTLY ARISING FROM THE SALE OR USE OF THIS PRODUCT.
THE LIMITED WARRANTY SET FORTH HEREIN IS IN LIEU OF ALL OTHER WARRANTIES OR REP-
RESENTATION, 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.
GIANT INDUSTRIES, INC., 900 N. Westwood Ave., Toledo, Ohio 43607 Phone (419) 531-4600, Fax (419) 531-6836, www.giantpumps.com Copyright 2013 Giant Industries, Inc.
10/13 P200A-5100.indd
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