Giant P200 Series User manual

Triplex Ceramic
Plunger Pump
Operating Instructions/
Repair and Service Manual
Contents:
Installation Instructions: page 2
Pump Specications: pages 3-5
Exploded View: page 6
Parts List / Kits: page 7
Torque Specications: page 8
Preventative Maintenance page 8
Repair Instructions: pages 9-10
Dimensions: page 11
Warranty Information: back page
316 Stainless Steel
Updated 10/18
Series
P200-12mm versions
For Models:
P205-5100
P205-5111
P205-5121
P205-5180
P206-5100
P206-5111
P206-5121
P206-5180
P209-5100
P209-5111
P209-5121
P209-5180

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.
Before any maintenance to the pump takes
place the pressure in discharge line and in
pump must be at zero. Close suction line. Dis-
connect fuses to ensure that the driving motor
is not accidently switched on.
Make sure that all parts on the pressure side of
the unit are vented before starting the pump. In
order to prevent air, or an air-water-mixture
being absorbed and to prevent cavitation
occurring, 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
standing nearby.
Giant Plunger Pumps are suitable for
pumping 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
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.
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
trouble-free water supply .
!Important! If there is a danger of frost, the
water in the pump and in the pump ttings
(particularly the unloader valve) must be
emptied. The second discharge port can also
be used and the pump run ‘dry’ for 1-2 min-
utes for this purpose.
Oil: Use only 8.1 ounces (0.24 litres) of Giant
Oil (p/n 01154) 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 the oil once per year.
Caution! When operating in damp places or
with high temperature uctuations. Should
condensate (frothy oil) occur in the gear box
the oil must be changed immediately.
Keep NPSH under control.
Maximum input pressure 145 PSI (10 bar),
maximum suction head -4.35 PSI (-0.3 bar).
Make sure that suction pulsation is sufciently
dampened - water column resonance must
be avoided.
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 maximum admissible operating pressure
can not be exceeded by more than 10 %.

3
Pump Specications
Max. Flow Nominal/
Intermittent Pressure
Max.
Speed
Plunger Diameter Stroke Power
Required
Model GPM l/min PSI bar RPM in mm in mm BHP kW
P205 0.5 2.0 2500 170 1750 0.47 12 0.13 3.4 0.86 0.64
P206 0.8 3.0 2500 170 1750 0.47 12 0.22 5.5 1.4 1.0
P209 1.5 5.7 2500 170 1750 0.47 12 0.39 10 2.6 1.9
*Positive inlet pressure required- Make sure that suction pulsation is sufciently dampened-water column
resonance must be avoided.
Common Specications U.S. Metric
Max. Temperature of Pumped Fluids ..................... 160 °F ..................................................................... 70 °C
Inlet Pressure ........................................................ 90 PSI ...................................................................6.2 bar
Inlet Ports .................................................................................................................................... (2) 1/2” BSP
Discharge Ports ........................................................................................................................... (2) 3/8” BSP
Shaft Rotation ...............................................................................................Top of Pulley Towards Fluid End
Crankshaft Diameter..............................................0.94” ...................................................................... 24 mm
Key Width .............................................................. 0.31” ........................................................................ 8 mm
Shaft Mounting ...............................................................................................................................Either Side
Weight ................................................................... 13.25 lbs. ...............................................................6.0 Kg
Crankcase Oil Capacity .........................................8.1 .oz. ............................................................ 0.24 Liter
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 sequence.
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.
Horsepower Ratings:
We recommend a 1.15 service factor be specied when selecting an electric motor as the power source.
To compute electric motor horsepower required, use the following formula: HP = (GPM X PSI) / 1450.
The formula to determine the horsepower required for a gas engine is: HP = (GPM X PSI) / 1150.
The formula to determine the horsepower required for a diesel engine is: HP = (GPM X PSI) / 1250.
For the Application of a Hydraulic Motor:
To Determine the Torque of a Hydraulic Motor -- (GPM x PSI x 36.77) / RPM = Torque (in-lbs)
Calculating RPM / GPM of Pump:
A pump must be connected to an electric motor or gas or diesel engine with the correct ratio of pulleys
and belts to attain the required speed and GPM. The use of a Variable Frequency Drive (VFD) may also
be used to control the RPM of a properly sized electric motor when variable ows are required.
(Max. Pump RPM / Rated Pump GPM) x Required Pump GPM = Required Pump RPM
To calculate a pulley diameter one (1) pulley diameter and the required pump RPM must be known:
(Pump RPM x Pump Pulley Diameter) / Motor RPM = Motor Pulley Diameter
(Motor RPM x Motor Pulley Diameter) / Pump RPM = Pump Pulley Diameter

4
P200-5100/-5111/-5121/5180 - 12mm - EXPLODED VIEW

5
P200-5100/-5111/-5121/-5180 SERIES
PARTS LIST - 12mm Versions
ITEM PART NO. DESCRIPTION QTY.
1 08300C Crankcase, Anodized 1
2 08301 Oil Dipstick with O-Ring 1
3 08302 Crankcase Cover, Short 1
3A 07190-0100 Drain Plug w/Gasket 1
4 08005 O-Ring 1
5 08185-0100 Oil Drain Plug with Gasket 1
6 07188-0100 Screw, Short Cover 4
6A 07223-0100 Spring Washer 4
7 08303 Bearing Cover I 2
8 08491 Sight Glass 1
9 07193 O-Ring 1
10 07225-0100 Hexagon Screw 8
10A 07223-0100 Spring Washer 8
11 08331 Radial Shaft Seal 1
12A 04917 Ball Bearing 1
12B 01086 Ball Bearing 1
13 04918 Crankshaft (P205) 1
13 03026 Crankshaft (P206) 1
13 04920 Crankshaft (P209) 1
14 06207 Woodruff Key 1
15 08333 Connecting rod 3
16 06641 Plunger Complete
(except -5180) 3
16 06641-0100 Plunger Complete
(-5180 only) 3
17 08442 Wrist Pin 3
19 08356 Oil Seal 3
20 06645-0100 Seal Case 3
21 08443 O-Ring 3
21 08443-0001 O-Ring
(-5111/-5121 versions) 3
ITEM PART NO. DESCRIPTION QTY
23 07391 V-Sleeve
(-5100/-5180 versions) 3
23 07391-0010 V-Sleeve (-5111 versions) 3
23 07391-0020 V-Sleeve (-5121 versions) 3
23A 08598 V-Sleeve, Weep
(-5100 versions) 3
23A 07391-0010 V-Sleeve (-5111 versions) 3
23A 07391-0020 V-Sleeve, Weep
(-5180/-5121 versions) 3
24 07392 Support Ring 6
25 06646-0100 Weep Return Ring 3
26 06582-5000 Valve Casing 1
26A 04273 Valve Assembly 6
27 07849-0100 Valve Seat 6
28 06809 Valve Plate 6
29 06816 Valve Spring 6
30 07907 Valve Spring Retainer 6
30A 06824 Spacer Ring 3
30B 05510-0100 Sleeve 3
30C 07489 O-Ring 3
30C 06015-0001 O-Ring
(-5111/-5121 versions) 3
31 07853-0001 O-Ring 6
32 07928-0100 Valve Plug 6
33 07913-0001 O-Ring (-5180 versions) 6
33 07913-0001 O-Ring (except -5180) 3
34 08316-0100 Hexagon Screw 8
36 12138 Plug, 3/8” BSP 1
36A 07109-0400 Plug, 1/2” BSP 1
P200-5100/-5111/-5121/-5180 REPAIR KITS
Part# 09656 (“-5100” Pumps)
Item Part # Description Qty.
21 08443 O-Ring 3
23 07391 V-Sleeve 3
23A 08598 V-Sleeve, weep 3
24 07392 Support Ring 6
Part# 09657 (“-5180” Pumps)
Item Part # Description Qty.
21 08443 O-Ring 3
23 07391 V-Sleeve 3
23A 07391-0020 V-Sleeve, weep 3
24 07392 Support Ring 6
Valve Assembly Kit
Part# 09775
Item Part # Description Qty.
26A 04273 Valve Assembly 6
31 07853-0001 O-Ring 6
33 07913-0001 O-Ring 6
Oil Seal Kit
Part# 09144
Item Part # Description Qty.
19 08356 Oil Seal 3
Part# 09656-0021 (“-5121” Pumps)
Item Part # Description Qty.
21 08443-0001 O-Ring 3
23 07391-0020 V-Sleeve 3
23A 07391-0020 V-Sleeve, weep 3
24 07392 Support Ring 6
Part# 09656-0011 (“-5111” Pumps)
Item Part # Description Qty.
21 08443-0001 O-Ring 3
23 07391-0010 V-Sleeve 3
23A 07391-0010 V-Sleeve, weep 3
24 07392 Support Ring 6
Plunger Packing Kits

6
REPAIR INSTRUCTIONS - P200-5100/-5111/-5121-5180 PUMPS - 12mm Versions
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 re-
place if damaged.
2. Using a needle nose pli-
ers, remove the inlet and
discharge valve assem-
blies (27-30) and o-ring
(31). Inspect all parts for
wear and replace as nec-
essary.
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 rear v-sleeve
(23A) from the seal case
(20). Inspect pressure
ring (24) behind the seal
case (20).Inspect all parts,
including o-ring (21) for
wear and replace as nec-
essary.
8. Check surfaces of
plunger (16). A dam-
aged surface will cause
accelerated wear on
the seals. Deposits of
any kind must be care-
fully removed from the
plunger surface. A dam-
aged plunger must be
replaced!
9. If the crankcase oil
seals (19) are to be
replaced, they can be
removed by rst remov-
ing the crankshaft (13),
connecting rods (15)
and plunger assembly
(16) from the gear end.
Then the oil seals can
be pushed out from the
rear. Please contact Gi-
ant for details.
4. Remove the o-ring (31)
Inspect all parts for
wear. 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
eight (8) socket head
cap screws (34).
6. Carefully slide the valve
casing (26) out over the
plungers.
10. If the ceramic plunger
pipe (16B) is damaged,
replace entire plunger
assembly by removing
crankshaft (13). Contact
Giant for further details.
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.

7
Reassembly sequence of the P200-5100/-5111/-5121/-5180 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). For the
P206/209 pumps, replace pressure ring (24) along with v-sleeve (23A).
3) Generously lubricate v-sleeve (23). Assemble v-sleeves (23) into sleeve (30B). Assemble
weep return ring (25) and pressure ring (24) over plungers (16). Assemble o-ring (30C)
over sleeve (30B) and place sleeve (30B) into valve casing (26). Slide valve casing over
plungers and seat rmly. Replace the eight socket head cap screws (34) and tighten to 88
inch-pounds (10-12 NM) in a crossing pattern.
4) Replace the six o-rings (31) and the six valve assemblies (26A). 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).
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]
REPAIR INSTRUCTIONS - P200-5100/-5111/-5121-5180 PUMPS - 12mm Versions
P200-5100 Lubrication Information/Torque Specication/Tool List
Item # Part # Description Lubrication Torque
3A 07190-0100 Drain Plug w/Gasket 22 ft.-lbs. (30 Nm)
5 08185-0100 Oil Drain Plug w/Gasket 22 ft.-lbs. (30 Nm)
607188-0100 Screw, Short Cover 88 in.-lbs. (10 Nm)
10 07225-0100 Hexagon Screw 88 in.-lbs. (10 Nm)
32 07928-0100 Valve Plug Pro Pack 550 55 ft.-lbs. (75 Nm)
34 08316-0100 Hexagon Screw 106 in.-lbs. (12 Nm)
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 7 for kit list)
Oil Seal Kit (1 kit/pump) X
(See page 7 for kit list)
Valve Spare Parts (1 kit/pump) X

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 consideration. Call (419)-531-4600 or fax [phone] 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.
10/18 P200-5100-12mm.indd
GIANT INDUSTRIES, INC., 900 N. Westwood Ave., Toledo, Ohio 43607
PHONE [phone], FAX [phone], www.giantpumps.com
 Copyright 2018 Giant Industries, Inc.
P200-5100/-5111/-5121/5180 - 12mm Version - DIMENSIONS - INCHES (mm)