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P220-3000
User Manual
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Giant P220-3000 User Manual

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Pump P220-3000
Triplex Ceramic Plunger Pump Operating Instructions/ Repair and Service Manual
Contents:
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 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.
2
Specifications
Volume ............................................................................................................ Up to 4.7GPM
Model P220-3000
Discharge Pressure ......................................................................................... Up to 2000 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) 3/8" BSP
Discharge Ports .............................................................................................. (2) 3/8" BSP
Shaft Rotation .................................................................................... Top of Pulley Towards Fluid End
Crankshaft Diameter....................................................................................... 24mm
Key Width ....................................................................................................... 8m 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 .............................................................. 0.95
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.
o
F
P220-3000 HORSEPOWER
REQUIREMENTS
RPM GPM 1000 PSI 1500 PSI 1700 PSI 2000 PSI
250 0.7 0.5 0.7 0.8 1.0
500 1.3 0.9 1.3 1.5 1.8 1000 2.7 1.9 2.8 3.2 3.7 1450 3.8 2.6 3.9 4.5 5.2 1750 4.7 3.2 4.9 5.5 6.5
3
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
Exploded View
P220-3000 Pump
P220-3000 Pumps
Plunger Packing Kit
Part # 09164
Item # Qty. Part # Description 23 3 08477 V-Sleeve, weep 23 A 3 08087 V-Sleeve, brown 24 3 07904 Pressure Ring
Valve Assembly Kit
Part # 09116
Item # Qty. Part # Description 32X 6 07946 V alve Assembly Complete 31 6 07853 O-Ring
Repair Kits
Oil Seal Kit
Part # 09144
Item # Qty. Part # Description 19 3 08356-0010 Oil Seal
4
Spare Parts
P220-3000 Pump
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 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 08467 Crankshaft 1 14 06207 Woodruff Key 1 15 08333 Connecting Rod 3 16 08469-0100 Plunger, Complete, 18mm 3 16 A 08468 Plunger Base 3 16B 08455 Plunger Pipe 3 16C 08456-0100 Tension Screw 3 16D 07204-0100 Crush Washer, 316 S.S. 3 17 08442 Wrist Pin 3 18 07770 O-Ring 3
ITEM PART NO. DESCRIPTION QTY.
16B 08455 Plunger Pipe 3 16C 08456-0100 Tension Screw 3 16D 07204-0100 Crush Washer, 316 S.S. 3 17 08442 Wrist Pin 3 18 07770 O-Ring 3 19 08356-0010 Oil Seal 3 20 08444 Seal Case 3 21 08443 O-Ring 3 23 08477 V-Sleeve, Weep 3 23 A 08087 V-Sleeve, Brown 3 24 07904 Pressure Ring 3 25 08445 Weep Return Ring 3 26 08446-5000 Valve Casing 3/8" Inlet Ports 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
Pump Torque Specifications
P220-3000
Position Item# Description Torque Amount
16C 08456-0100 Tension Screw, Plunger 220 (in.-lbs.)
32 07928 Valve Plug 59 (ft.-lbs.) 34 08316 Hex Head Cap Screw, Valve Casing 105 (in.-lbs.)
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)
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REPAIR INSTRUCTIONS - P220-3000 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.
4. Remove the o-ring (31). Inspect all parts for wear and replace as necessary. 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 (23A) 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!
6
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 - P220-3000 PUMP
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
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.
plunger base (16A). (For pumps that use the 316 S.S. crush washer (16D), fatten the washer prior to plunger reassembly)
Replace the plunger with the new one and locktite the plunger bolt and torque to 220 inch-pounds.
Reassembly sequence of the P220-3000 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 (23A) 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). Apply one drop of Loctite 243 to the valve plugs (32) and tighten to 59 ft.-lbs.
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 (1 Quart) p/n 1153 X X Seal Spare Parts (1 kit/pump) X
(See page 4 for kit list) Oil Seal Kit (1 kit/pump) X
(See page 4 for kit lit)
Valve Spare Parts (1 kit/pump) X
(See page 4 for kit list)
NOTE: Contact Giant Industries for Service School Information. Phone: (419)-531-4600
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P220-3000 DIMENSIONS (inches)
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:
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:
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 (419)-531-6836 to obtain an R.G.A. number.
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.
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.
prior to the return to Giant Industries of all products
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.
GIANT INDUSTRIES, INC., 900 N. Westwood Ave., P.O. Box 3187, Toledo, Ohio 43607 PHONE (419) 531-4600, FAX (419) 531-6836, www.giantpumps.com Ó Copyright 2002 Giant Industries, Inc.
4/02 P220-3000.PM6
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