Giant P208 Repair and User manual

Model
P208-B
Triplex Ceramic
Plunger Pump
Operating Instructions/
Repair and Service
Manual
Contents:
Installation Instructions: page 2
Pump Specications: page 3
Exploded View: page 4
Parts List/Repair Kits: page 5
Torque Specications: page 5
Repair Instructions: pages 6-7
Preventative Maintenance/
Recommended Spare Parts List: page 7
Dimensions: back page
Warranty Information: back page
P208 Pump with Brass Valve Retainers

2
Installation Instructions
When the pump is in operation, the drive shaft
end and the coupling must be covered up by
either a contact-protector or by a coupling bell.
Pressure in discharge line and in pump must
be at zero before any maintenance to the
pump takes place. Close up suction line. Dis-
connect fuses to ensure that the driving motor
does not get switched on accidentally.
Make sure that all parts on the pressure side
of the unit are vented before starting the pump.
In order to preven air, or an air-water mixture
being absorbed and to prevent cavitation oc-
curring, the pump NPSHR suction head and
water temperature must be kept under control.
Cavitation and/or compression of gases
lead to uncontrollable pressure kicks which
can ruin pump and unit parts and also be
dangerous to the operator or anyone stand-
ing nearby.
Giant Plunger Pumps are suitable for pump-
ing clean water and other non-agressive or
abrasive media with a specic weight similar to
water.
Before pumping other liquids - especially
inammable, explosive and toxic media -
the pump manufacturer must under all cir-
cumstances be consulted with regard to the
resistance of the pump material. It is the re-
sponsibility of the equipment manufacturer
and/or operator to ensure that all pertinent
safety regulations are adhered to.
Required NPSH refers to water: specic weight
1kg/dm3, viscosity 1°E at maximum permissible
revolutions.
Operation and Maintenance
Check oil level prior to starting and ensure a
trouble-free water supply.
Important! If there is a danger of frost, the
water in the pump and in the pump ttings (par-
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.
Oil: Use only SAE 20W-50 (p/n 01153). Use
7.5 uid ounces (0.22 L) for short crankcase
covers and 9.0 uid ounces (0.27 L) for extend-
ed crankcase covers.
Initial change after 50 operating hours and then
every 500 operating hours, after 1 year if used
less.
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.
Maximum input pressure 145 PSI (10 bar),
maximum suction head -4.35 PSI (-0.3 bar).
Make sure suction pulsation is su󰀩ciently
dampened - water column resonance must be
avoided.
Safety Rules
Pump operation witout 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
maximum admissible operating pressure can
not be exceeded by more than 10%.

3
Specications
Model P208
HORSEPOWER RATINGS:
The rating shown are the power re-
quirements 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 horse-
power requirements, use the follow-
ing formula:
HP = (GPM X PSI) / 1450
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.
*Intermittent duty only
1750 RPM+.........................................................................................U.S. Metric
Flow (Continuous) @ 2000 PSI (140 Bar) .... 1.0 GPM.................... 3.8 LPM
Flow (Intermittent) @ 2500 PSI (175 Bar) .... 1.0 GPM ................... 3.8 LPM
3450 RPM+
Flow (Continuous) @ 2000 PSI (140 Bar) .... 1.9 GPM.................... 7.2 LPM
Flow (Intermittent) @ 2000 PSI (140 Bar) .... 1.9 GPM.................... 7.2 LPM
Maximum Inlet Pressure............................... 145 PSI ..................... 10 Bar
Plunger Diameter.......................................... 0.47”.......................... 12 mm
Stroke ...........................................................0.28”.......................... 7 mm
Max. Temperature of Pumped Fluids............ 160o F........................ 70o 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................................................................................. Either Side
Weight........................................................... 11.7 lbs...................... 5.3 Kg
Crankcase Oil Capacity ................................ 7.5 .oz. .................... 0.22 Liters
Extended Crankcase Oil Capacity................ 9.0 .oz. .................... 0.27 Liters
Volumetric E󰀩ciency @ 1750 RPM ................................................. 0.94
Volumetric E󰀩ciency @ 3450 RPM ................................................. 0.87
Mechanical E󰀩ciency @ 3450 RPM................................................ 0.86
+Positive inlet pressure required
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 se-
quence.
P208 HORSEPOWER REQUIREMENTS
RPM GPM 1000 PSI 1500 PSI 2000 PSI 2500 PSI*
250 0.14 0.1 0.1 0.2 0.2
500 0.29 0.2 0.3 0.4 0.5
1000 0.57 0.4 0.6 0.8 1.0
1750 1.00 0.7 1.0 1.4 1.7
3000 1.60 1.1 1.7 2.2 2.8
3200 1.80 1.2 1.9 2.5 3.1
3450 1.90 1.3 2.0 2.6 3.3

4
Exploded View - P208-B

5
ITEM PART NO. DESCRIPTION QTY.
17 08442 Wrist Pin 3
19 08356 Oil Seal 3
20 06645 Seal Case 3
21 08443 O-Ring 3
23 07391 V-Sleeve 3
23A 08598 V-Sleeve, Weep 3
24 07392 Support Ring 3
25 06646 Weep Return Ring 3
26 06647 Valve Casing 1
27 07849 Valve Seat 6
28 07491 Valve Plate 6
29 07906 Valve Spring 6
30 07907-B Valve Spring Retainer 6
31 07853 O-Ring 6
32 07928 Valve Plug 6
32X 07946AG-B Valve Assembly Complete 6
33 07913 O-Ring 6
34 08316 Hex Head Cap Screw 8
38 13338 Plug, 3/8” BSP 1
38A 07661 Seal 1
39 07109 Plug, 1/2” BSP 1
39A 08486 Copper Seal Ring 1
P208-B Parts List
ITEM PART NO. DESCRIPTION QTY.
1 08300C Crankcase 1
2 06773 Oil Dipstick with O-Ring 1
3 08302 Crankcase Cover, Short 1
3 08302-L Crankcase Cover, Long 1
3A 07190 Drain Plug 1
3B 13262 Gasket for drain plug 1
4 08005 O-Ring 1
5 06273 Oil Drain Plug with Gasket 1
5A 08192 Gasket 1
6 07188 Screw, Short Cover 4
6A 01176-2 Spring Washer 12
7 08303 Bearing Cover I 2
8 08491 Sight Glass 1
9 07193 O-Ring for Sight Glass 1
10 07225 Screw with Lock Washer 8
11 08331 Radial Shaft Seal 1
12A 04917 Ball Bearing 1
12B 01086 Ball Bearing 1
13 04922 Crankshaft 1
14 06207 Fitting Key 1
15 08333 Connecting Rod 3
16 06641 Plunger, Complete 3
Plunger Packing Kit
Part # 09527
Item # Part # Description Qty.
21 08443 O-Ring 3
23 07391 V-Sleeve, weep 3
23A 08598 V-Sleeve 3
24 07392 Support Ring 3
Valve Assembly Kit
Part # 09116
Item # Part # Description Qty.
32X 07946AG-B 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 Oil Seal 3
Optional Teon Packing Kit
Part # 09527-0021
Item # Part # Description Qty.
21 08443-0001 O-Ring 3
23/23A 07391-0020 V-Sleeve, Teon 6
24 07392 Support Ring 3
31 07853-0001 O-Ring, Viton 6
33 07913-0001 O-Ring, Viton 6
P208-B Torque Specications
P208-B Repair Kits
Item Part No. Description Lubrication Torque Amount
3A 07190 Drain Plug 22 ft.-lbs. (30 Nm)
506273 Oil Drain Plug w/Gasket 22 ft.-lbs. (30 Nm)
607188 Screw, Short Cover 88 in.-lbs. (10 Nm)
10 07225 Screw w/Lock Washer 88 in.-lbs. (10 Nm)
32 07928 Valve Plug Loctite 243 55 ft.-lbs. (75 Nm)
34 08316 Hex Head Cap Screw 106 in.-lbs. (12 Nm)

6
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.
2. Using a needle nose
pliers, remove the inlet
and discharge valve
assemblies (32X).
3. By inserting a small
screw driver between
the valve seat (27) and
the valve spring retainer
(30), the valve assembly
can be separated.
7. Remove the weep return
ring (25), pressure ring
(24), and v-sleeve (23)
from the valve casing
(26). Remove the weep
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!
9. If the crankcase oil
seals (19) are to be
replaced, they can
be removed by rst
removing the crankshaft
(13), connecting rod
(15), and plunger
assembly (16) from the
gear end.
Then the oil seals can
be pushed out from the
rear. Please contact
Giant for details.
4. Remove the o-ring (31).
Inspect all parts for wear
and replace as necessary.
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).
5. Next, use a 5mm allen
wrench to remove the 8
socket head cap screws
(34).
6. Carefully slide the valve
casing (26) out over the
plungers.
Repair Instructions - P208-B PUMP

7
Reassembly sequence of the P208-B PUMP
1) If oil seals (19) were removed, replace with seal lip towards crankcase. Lubricate seals before
replacing. Contact Giant for assistance with the reassembly of the gear end.
2) Replace seal case (20) with o-rings (21) over plungers. Generously lubricate o-rings and oil seal
before reassembly. Replace weep v-sleeve (23A) over plungers (16).
3) Generously lubricate v-sleeve (23). Assemble v-sleeves (23) into valve casing (#26). Assemble
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). Apply one drop of Loctite 243 to the valve plugs (32) and tighten to 55 ft.-lbs. (75 Nm).
Repair Instructions - P208-B PUMP
NOTE: Contact Giant Industries for Service School Information. Phone: [phone]
For maintenance of the gear end of your pump contact Giant Industries or your local
distributor. Phone: [phone]
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.
10. If the ceramic plunger
pipe (16) is damaged,
replace entire plunger
assembly by removing
crankshaft (13). Contact
Giant for further details.
Check Daily Weekly 50 Hrs.
Every
500
Hours
Every
1500
Hours
Every
3000
Hours
Oil Level/Quality X
Oil Leaks X
Water Leaks X
Belts, Puelly X
Plumbing X
Oil Change (1 quart) p/n 01153 X X
Seal Spare Parts (1 kit/pump)
(see page 12 for kit list)
X
Oil Seal Kit (1 kit/pump)
(see page 12 for kit list)
X
Valve Spare Parts (1 kit/pump)
(see page 12 for kit list)
X
Preventative Maintenance Check List & Recommended Spare Parts List
Recommended Spare Parts
(See page 5 for kit list)
(See page 5 for kit list)
(See page 5 for kit list)

01/22 P208-B.indd
GIANT INDUSTRIES, INC., 900 N. Westwood Ave., Toledo, Ohio 43607
PHONE [phone] FAX [phone], www.giantpumps.com
 Copyright 2022 Giant Industries, Inc.
P208-B 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. Five (5) years from the date of shipment for all pumps used in portable pressure
washers with NON-SALINE, clean water applications.
2. Two (2) years from the date of shipment for Giant pumps used in car wash
applications.
3. One (1) year from the date of shipment for all other Giant industrial and consumer
pumps.
4. Six (6) months from the date of shipment for all rebuilt pumps
5. 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 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.
WARNING: This product might contain a chemical known to the State of California to cause cancer,
and birth defects or other reproductive harm.
For more information go to www.P65Warnings.ca.gov