Exploded View : page 4
Parts List/Kits: page 5
Torque Specs/Pump Mounting
Selection Guide/
Preventative Maintenance: page 7
Repair Instructions: pages 8 -11
Dimensions: back page
Warranty Information: back page
Page 2
INSTALLATION INSTRUCTIONS
Required NPSH refers to water: Specic weight 62.4 lb/
3
ft
(1kg/dm3) at maximum permissible revolutions.
Operation and Maintenance
Check oil level prior to starting and ensure trouble-free wa-
ter supply. Oil: Use only 23.7 ounces (0.7 litres) of Giant Oil
(p/n 01154) or ISO VG 220 GL4 (e.g. Aral Degol BG220) or
SAE 90 GL4 gear oil.
Initial change after 50 operating hours and then every 500
operating hours. In either case change oil every 6 months
operation.
Caution! When operating in damp places or with high
temperature uctuations.
Oil must be changed immediately, should condensate
(frothy oil) occur in the gear box.
Keep NPSH under control.
Max. input pressure 145 PSI (10 bar), maximum suction
head -4.35 (-0.3 bar).
Important! Do not use grease when renewing the high
pressure plunger seal (pos. 50).
Hot water causes grease to wash off the seal which in turn
can jam valves!
The new seals should only be oiled lightly before installation.
These operating instructions supplement the general operating instructions for the SP series pumps.
Plant Lay-Out
For perfect functioning of the pump, the following points
must be adhered to.
A) Pressure in Suction Side
The stipulated NPSHR is the minimum required pressure
above the vapor pressure of the medium and is never to
fall short of this gure. Temperature and vapor pressure of
the medium, the geodetical height of the location, the ow
rate and loss of friction in the suction line, must all be taken
into consideration.
Safety Rules
Pump operation without safety valve as well as any excess in temperature or speed limits automatically voids the
warranty. The safety valve must be regulated in accordance with the guidelines for liquid spraying units so that
the admissible operating pressure can not be exceeded by
more than 10%.
When the pump is in operation, the open shaft end must
be covered up by shaft protector (17), the driven shaft side
and coupling by a contact protector.
Pressure in discharge line and in pump must be at zero
before any maintenance to the pump takes place. Close
up suction line. Disconnect fuses to ensure that the driving
motor does not get switched on accidently.
Make sure that all parts on the pressure side of the unit are
vented and relled, with pressure at zero, before starting
the pump.
In order to prevent air, or an air/water-mixture being
absorbed and to prevent cavitation occurring, the pumpNPSHR, positive suction head and water temperature must
be kept under control.
Cavitation and/or compression of gases lead to uncon-
trollable pressure-kicks which can ruin pump and unit
parts and also be dangerous to the operator or anyone
standing nearby.
Giant Plunger Pumps are suitable for pumping clean water
and other non-agressive or abrasive media with a specic
weight similar to water.
B) Pulsation
Due to its construction, the plunger pump creates pulsation in the suction and discharge lines. Suction pulsation in
particular must be dampened in order to prevent resonance
in the suction line which in turn, causes cavitation. Therefore, the pump is never to be connected by a rigid pipe but
rather by a exible hose (not reinforced by steel), and if
possible 1.5 to 2 times wider than the suction connection. If
a booster pump is used attach a hose between the booster
pump and the high pressure pump.
If several pumps are used, each pump must have its own
suction line. If this can’t be done, a suction air chamber or
a suction ow stabilizer must be installed in front of each
pump. The bladder in the stabilizer is to be pre tensioned
on location.
Depending on the lay-out of the plant, a pressure accumulator may be necessary on the discharge side. This pressure accumulator must be installed right behind the discharge outlet of the high pressure pump. We recommend
the use of only one pressure accumulator in the discharge
line in order to avoid irritation which could be caused by
different pre-tension levels in the accumulators.
Gas-tension in both the suction ow stabilizer and in the
pressure accumulator are to be checked regularly.
Before pumping other liquids - especially inammable,
explosive and toxic media - the pump manufacturer
must under all circumstances be consulted with
regard to the resistance of the pump material. It is the
responsibility of the equipment manufacture and/or
operator to ensure that all pertinent safety regulations
are adhered to.
Please read operating instructions carefully before
putting the pump into operation!
Maintenance
Important! To lubricate the high pressure seals, the inter-
mediate casing (48) is lled with high-temperature resistant
grease at our works. This means the holes in the valve
casing have to be closed with thread plugs (29A) - to be
Crankshaft Mounting....................................................................................................Either Side
Shaft Rotation ...................................................... Top of Pulley Towards Fluid End
Weight .................................................................. 31.3 lbs. ........................................... (14.2 kg)
NPSHR (900 RPM) ..............................................21.3 ft. of head .................................. 6.5 mWs
Consult the factory for special requirements that must be met if the
pump is to operate beyond one or more of the limits specied above.
o
F ................................................... (90o C)
SP100HT HORSEPOWER REQUIREMENTS
RPMGPMGPH200 PSI400 PSI600 PSI870 PSI
2502.0120.00.280.550.831.2
5003.9234.00.541.081.612.34
7505.9354.00.811.632.443.54
9007.1426.00.981.962.944.26
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 1.1 service factor be speci-
ed when selecting an electric motor as the power
source. To compute specic pump horsepower
Crankshaft Mounting....................................................................................................Either Side
Shaft Rotation ....................................................... Top of Pulley Towards Fluid End
Weight ...................................................................31.3 lbs. ........................................... (14.2 kg)
NPSHR (900 RPM) ...............................................20.3 ft. of head ................................. 6.2 mWs
Consult the factory for special requirements that must be met if the
pump is to operate beyond one or more of the limits specied above.
o
F .................................................. (90o C)
SP200HT HORSEPOWER REQUIREMENTS
RPMGPMGPH200 PSI400 PSI600 PSI870 PSI
2501.7102.00.230.470.701.02
5003.4204.00.470.941.412.04
7505.0300.00.691.382.073.00
9006.1366.00.841.682.523.66
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 1.1 service factor be speci-
ed when selecting an electric motor as the power
source. To compute specic pump horsepower
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 p/n 1154 X X
Plunger Packing Kits (1 kit/pump) X
(See page 5 for kit list)
Valve Assembly Kit (1 kit/pump) X
(See page 5 for kit list)
7
Page 8
REPAIR INSTRUCTIONS - SP100HT/SP200HT PUMP
41A 44 34 35 36
1. With a 22mm socket, remove
the three discharge (43)
and three inlet (41) manifold
plugs.
3. Use a small slide hammer
to remove valve seats (37)
from manifold (29). Inspect
valve plate (36) and valve
seats (37) for wear. If exces-
sive pitting is seen, replace
the worn parts. Check valve
seat o-ring (38) for wear and
replace as necessary.
2. Check o-ring (44) for wear and replace as necessary. Remove the
discharge spring retainer (34), valve spring (35), and valve plate
(36).
4. Drain the oil from the pump.
Turn the pump over to remove
the four manifold stud nuts
(46) with a 19mm wrench.
5. Tap the back of the valve cas-
ing (29) with a rubber mallet.
6. Remove the inlet valve retainer assembly (34A-39)
40 36 35 34A
7. Remove the o-ring, (40), valve plate (36), valve spring (35), spring
retainer (34A). Check valve retainer o-ring (40) for wear.
8
Page 9
REPAIR INSTRUCTIONS - SP100HT/SP200HT PUMP
8. With a valve puller remove
the valve seat (37) and o-ring
(38) replace if worn. If exces-
sive pitting is seen, replace
the worn parts. Check valve
seat o-ring (38) for wear and
replace as necessary.
10. With a at headed screw-
driver remove the weep return
plate (48). Remove the o-ring
(49) and check for wear.
9. Remove the spacer (39A), pressure spring (33), support ring (51),
sleeves (50), and pressure ring (30), from the manifold (29) and
check for wear.
49
50A
51A
11. Inspect seals (50A), seal
support ring (51A) and O-ring
(49) and replace as neces-
sary.
12. Inspect ceramic plunger
(24A) tips for wear. If necessary, replacement of the
ceramic plungers may be accomplished by removing the
plunger bolt assemblies (24)
with a 13mm wrench. Ce-
ramic plungers should now
slide off the stainless steel
plunger base (22). Excessive resistance to plunger
removal may be overcome
by heating the stainless steel
plunger base. This will melt
any excess loc-tite beneath
the ceramic plunger allowing
easy removal.
9
Page 10
REPAIR INSTRUCTIONS - SP100HT/SP200HT PUMP
24E14. To replace plunger oil seals (26),
13. Replace copper ring (24E)
onto plunger bolt (24B). Slide
plunger bolt assembly (24) into
ceramic plunger (24A). Apply
a light lm of loc-tite to plunger
bolt threads and place plunger
assembly onto stainless steel
plunger base (22) and tighten to
247 in.-lbs. (28 Nm).
proceed to “Gear End Disassembly”
section below. Otherwise, continue
as described below.
15. Before replacing pump manifold
(29), rst rotate crankshaft (18) until
two outside plungers (24A) extend
evenly forward. Next lubricate
v-sleeves (50) in the rear v-sleeve
housing (48) and slide housing over
plungers.
Important! Do not use grease on the
seals. Lubricate ceramic plungers
with a light lm of oil. Carefully and
evenly slide manifold over plungers
and press manifold rmly against
crankcase (1). Replace manifold stud
bolts (45), washers (47) and nut (46)
and tighten to 59 ft.-lbs. (80 Nm).
Gear End Disassembly
16. Remove the crankcase cover screws (9). Inspect the crankcase cover o-ring (4) for wear. Replace if necessary.
17. Inspect the dipstick (5) vent hole for signs of clogging. Clean if necessary.
18. To remove the crankshaft (18), rst remove the bearing cover plates (12). Remove the key (19).
19. With a 5 mm allen wrench remove the connecting rod screws (21) and rear portion of connecting rod assemblies
(20). Push the connecting rod (20) and plunger rod (22) down as far as possible into the crankcase housing.
20. Hold the pump rear assembly with a wooden xture, or other suitable device, in order to secure it while removing
the crankshaft (18). Using a plastic mallet, tap the crankshaft from one side while turning it from the other side.
The turning insures that during this sequence the crankshaft does not become wedged against the front portion
of the connecting rods (20). The far side bearing (15) will remain in the crankcase (1). When free, the crankshaft
can be removed by hand. The opposite side crankshaft seal (14) will be removed by this procedure. It is impor-
tant that you turn the crankshaft (18) constantly while tapping from the opposite end to avoid any binding.
The crankshaft bearing (15) remains on the crankshaft as it is removed. If necessary, use a bearing puller to
remove the crankshaft bearing (15).
21. Remove the front portion of the connecting rods (20) and plunger base assembly (22) from the rear of the pump by
pulling straight out of the crankcase crosshead guides. Notice that the connecting rod (20) halves are numbered or colored. Connecting rods must be positioned with their numbers or colors on the upper left-hand
side, in the same numerical sequence as when they were removed.
22. Using a dowel and a rubber mallet, tap the oil seals (26) out from the rear of crankcase (1). The area onto which
the oil seal rests should be clean and dry. Put a small drop of loc-tite on the oil seals and place into crankcase
with lips facing the rear of the pump.
23. To remove the crosshead pin (23) from the crosshead (22), the assembly should be positioned on a wooden xture
to avoid damage to crosshead. Drive out the pin on opposite side of mark located on the crosshead. On those
pumps without mark on crosshead, drive out pin by tapping on tapered side of pin.
10
Page 11
REPAIR INSTRUCTIONS - SP100HT/SP200HT PUMP
24. To remove the bearing (15) remaining in the crankcase (1), insert small end of Giant bearing tool and tap
with a rubber mallet until bearing and seal (14) are completely removed. The bearing can only be removed
from the inside by inserting the Giant Bearing Tool through the opposite side of the crankcase. The
crosshead guide in the crankcase should be inspected for possible damage.
25. To reassemble, place the far bearing (15) in the crankcase (1) bearing housing and with the Giant Bearing
tool as a driver, tap into the crankcase using a rubber mallet.
26. Insert the far side crankshaft oil seal (14) with the Giant Bearing Tool making sure it is rmly seated and well
oiled. Always make sure that the crankshaft seal lip does not show signs of wear and that the garter spring
is rmly in place on the seal before reinserting into the pump. Replace the bearing cover (12) and o-ring (13)
and tighten securely.
27. Replace the front portion of the connecting rod (20) and plunger rod/ crosshead assembly (22) by press-tting
the crosshead pin (23). Make sure to insert the beveled edge of the crosshead pin into crosshead. If the
crosshead has a mark, install pin from marked side. The crosshead pin (23) should not extend beyond
either side of the crosshead (22) in order to prevent damage to the crosshead bore of the crankcase
(1).
28. Place each crosshead/ plunger assembly into the pump making sure that all of the parts are well oiled before
insertion into the crankcase (1). Notice that the connecting rod (20) halves are numbered or colored.
Connecting rods must be positioned with their numbers or colors on the upper left-hand side, in the
same numerical sequence as when they were removed.
29. Replace near side bearing (15) on crankshaft by using the Giant Bearing Tool and mallet to tap into place.
Take the crankshaft (18) end with the bearing (15) and insert the other end through the bearing housing and
tap with a rubber mallet until the bearing is seated.
30. When reassembling the connecting rods (20), note that the connecting rod halves are numbered or colored
and that the numbers or colors must be matched and aligned. Torque the connecting rod bolts to 22 ft.-lbs.
(30 Nm).
31. Insert the near side crankshaft oil seal (14) with the Giant Bearing Tool making sure it is rmly seated and well
oiled. Replace the bearing cover (12) and o-ring (13) and tighten securely.
See instructions above for re-installing uid end onto the gear end.
32. Fill the pump crankcase (1) with 24 oz. (710 mL) of Giant Industries’ oil and check the oil level with the dipstick (5). Proper level is center of two lines. Reinstall the pump into your system.
NOTE: Contact Giant Industries for Service School Information. Phone: (419)-531-4600
11
Page 12
SP100HT/SP200HT DIMENSIONS - INCHES (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 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 modications made by the customer or third party.
6. The operation of pumps and or accessories exceeding the specications 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 (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.