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Giant P200A-5100 Series Repair and User manual

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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
Triplex Ceramic
Plunger Pump
Operating Instructions/
Repair and Service Manual
Updated 10/13
316 Stainless Steel Models:
P217A-5100, P218A-5100, P219A-5100,
P220A-5100, P221A-5100, P227A-5100,
P230A-5100
P200A-5100
SERIES PUMPS
18mm Versions
2
INSTALLATION INSTRUCTIONS
4. Use of a dampener is necessary to minimize
pulsation at drive elements, plumbing, con-
nections, 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 desig-
nated by the arrows on the pump crankcase.
Reverse rotation may be safely achieved by fol-
lowing 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. Cavi-
tation 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.
IMPORTANT OPERATING CONDITIONS
Failure to comply with any of these conditions invalidates the warranty.
2. Pump operation must not exceed rated pres-
sure, 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.
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 operat-
ing conditions.
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 instal-
lation. 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
to ensure optimum lubrication.
2. The inlet to the pump should be sized for the
ow rate of the pump with no unnecessary re-
strictions 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
(30oC), 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 ow rate to pre-
vent line pressure loss to the work area. It is es-
sential 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.
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.
o
o
3
Specications
Model P217A-5100
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.
U.S. (Metric)
1750 RPM *
Ratings......................................................1.85 GPM @ 2000 PSI.....(7.0 LPM @ 140 bar)
3450 RPM *
Ratings......................................................3.6 GPM @ 2000 PSI.......(13.8 LPM @ 140 bar)
Plunger Diameter......................................0.71” ................................. 18mm
Stroke .......................................................0.22” ................................. 5.5mm
Temperature of Pumped Fluids..................Up to 86oF ......................(30oC)
Inlet Ports ...........................................................................................(2) 1/2” BSP
Discharge Ports..................................................................................(2) 3/8” BSP
Shaft Rotation.....................................................................................Top of Pulley Towards Fluid End
Crankshaft Diameter.................................0.94” .................................24mm
Key Width .................................................0.31” .................................8mm
Shaft Mounting....................................................................................Either Side
Weight.......................................................13 lbs. 4oz. ......................(6.0 kg)
Crankcase Oil Capacity............................8.1 .oz. ...........................(0.24 liters)
Volumetric Efciency @ 1750 RPM....................................................0.90
Mechanical Efciency @ 1750 RPM ..................................................0.88
*15 PSI inlet pressure required
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 vari-
ations 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 re-
quirements 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 =HP
1450
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
4
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.
Specications
Model P218A-5100
U.S. (Metric)
Volume .......................................................3.4 GPM ...........................(12.8 LPM)
Discharge Pressure....................................2000 PSI ..........................(140 bar)
Inlet Pressure .............................................90 PSI ..............................(6.2 bar)
RPM.......................................................................................................Up to 1750 RPM
Plunger Diameter........................................0.71”..................................18mm
Stroke.........................................................0.39” ..................................10.0mm
Temperature of Pumped Fluids ..................Up to 86oF ........................(30oC)
Inlet Ports .............................................................................................(2) 1/2” BSP
Discharge Ports.....................................................................................(2) 3/8” BSP
Shaft Rotation........................................................................................Top of Pulley Towards Fluid End
Crankshaft Diameter...................................0.94” ..................................24mm
Key Width...................................................0.31” ..................................8mm
Shaft Mounting ......................................................................................Either Side
Weight.........................................................13 lbs. 4 oz. ......................(6.0 kg)
Crankcase Oil Capacity..............................8.1 .oz. ............................(0.24 liters)
Volumetric Efciency @ 1750 RPM.......................................................0.96
Mechanical Efciency @ 1750 RPM .....................................................0.85
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. Thedesiredpressureisachievedbyselecting
the correct nozzle size that corresponds with the
pump GPM.
HORSEPOWER INFORMATION
Horsepower ratings 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 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 = HP
1450
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
5
Specications
Model P219A-5100
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. Thedesiredpressureisachievedbyselecting
the correct nozzle size that corresponds with the
pump GPM.
HORSEPOWER INFORMATION
Horsepower ratings 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 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 = HP
1450
U.S. (Metric)
Volume ....................................................4.2 GPM .................. (15.9 LPM)
Discharge Pressure.................................2000 PSI ................. (140 bar)
Inlet Pressure...........................................90 PSI ..................... (6.2 bar)
RPM........................................................................................... Up to 1750 RPM
Plunger Diameter.....................................0.71”......................... 18mm
Stroke ......................................................0.49” ......................... 12.4mm
Temperature of Pumped Fluids................Up to 86oF ............... (30oC)
Inlet Ports .................................................................................. (2) 1/2” BSP
Discharge Ports......................................................................... (2) 3/8” BSP
Shaft Rotation............................................................................Top of Pulley Towards Fluid End
Crankshaft Diameter................................0.94” ......................... 24mm
Key Width ................................................0.31” ......................... 8mm
Shaft Mounting........................................................................... Either Side
Weight......................................................13 lbs. 4 oz. ............ (6.0 kg)
Crankcase Oil Capacity...........................8.1 .oz. ................... (0.24 liters)
Volumetric Efciency @ 1750 RPM........................................... 0.96
Mechanical Efciency @ 1750 RPM ......................................... 0.85
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
6
Specications
Model P220A-5100
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. Thedesiredpressureisachievedbyselecting
the correct nozzle size that corresponds with the
pump GPM.
HORSEPOWER INFORMATION
Horsepower ratings 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 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 = HP
1450
U.S. (Metric)
Volume.......................................................4.7GPM*.................. (17.6 LPM)*
Discharge Pressure...................................2000 PSI .................. (140 bar)
Inlet Pressure.............................................90 PSI ...................... (6.2 bar)
RPM.............................................................................................. Up to 1750 RPM
Plunger Diameter.......................................0.71”.......................... 18mm
Stroke ........................................................0.56”.......................... 14.1mm
Temperature of Pumped Fluids..................Up to 86oF ............... (30o C)
Inlet Ports ..................................................................................... (2) 1/2” BSP
Discharge Ports............................................................................ (2) 3/8” BSP
Shaft Rotation...............................................................................Top of Pulley Towards Fluid End
Crankshaft Diameter..................................0.94”.......................... 24mm
Key Width ..................................................0.31”.......................... 8mm
Shaft Mounting.............................................................................. Either Side
Weight........................................................13 lbs. 4oz. .............. (6.0 kg)
Crankcase Oil Capacity.............................8.1 .oz. ................... (0.24 liters)
Volumetric Efciency @ 1750 RPM.............................................. 0.96
Mechanical Efciency @ 1750 RPM ............................................ 0.85
*Positive inlet pressure required
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
7
Specications
Model P221A-5100
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:
The rating shown are the power requirements
for the pump. Gas engine power outputs must
be approximately twice the pump power re-
quirements 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
U.S. (Metric)
1750 RPM *
Ratings.....................................................2.34 GPM @ 2000 PSI......(8.9 LPM @ 140 bar)
3450 RPM *
Ratings.....................................................4.6 GPM @ 2000 PSI........(17.6 LPM @ 140 bar)
Inlet Pressure...........................................-4.35 to 145 PSI ................(-0.3 to 10 bar)
RPM....................................................................................................Up to 3450 RPM
Plunger Diameter.....................................0.71”..................................18mm
Stroke ......................................................0.28” ..................................7.0mm
Temperature of Pumped Fluids................Up to 86oF.........................(30oC)
Inlet Ports ...........................................................................................(2) 1/2” BSP
Discharge Ports..................................................................................(2) 3/8” BSP
Shaft Rotation.....................................................................................Top of Pulley Towards Fluid End
Crankshaft Diameter...........................................................................24mm
Key Width ...........................................................................................8mm
Shaft Mounting....................................................................................Right Side Facing Manifold
Weight......................................................13 lbs. 4oz.........................(6.0 kg)
Crankcase Oil Capacity...........................8.1 .oz..............................(0.24 liter)
Volumetric Efciency @ 1750 RPM....................................................0.95
Volumetric Efciency @ 3450 RPM....................................................0.87
Mechanical Efciency @ 1750 RPM ..................................................0.86
*Positive inlet pressure required
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
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. Thedesiredpressureisachieved by select-
ingthe correctnozzle sizethat correspondswith
the pump GPM.
P221A-5100
8
Specications
Model P227A-5100
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:
The rating shown are the power requirements
for the pump. Gas engine power outputs must
be approximately twice the pump power re-
quirements 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
U.S. (Metric)
1750 RPM *
Ratings.......................................................2.1 GPM @ 2000 PSI .......(8.0 LPM @ 140 bar)
3450 RPM *
Ratings.......................................................3.8 GPM @ 2000 PSI .......(14.4 LPM @ 140 bar)
Inlet Pressure.............................................-4.35 to 145 PSI ................(-0.3 to 10 bar)
RPM......................................................................................................Up to 3450 RPM
Plunger Diameter.......................................0.71”..................................18mm
Stroke ........................................................0.25”..................................6.3mm
Temperature of Pumped Fluids..................Up to 86oF ........................(30oC)
Inlet Ports .............................................................................................(2) 1/2” BSP
Discharge Ports....................................................................................(2) 3/8” BSP
Shaft Rotation.......................................................................................TopofPulley TowardsFluid End
Crankshaft Diameter.............................................................................24mm
Key Width .............................................................................................8mm
Shaft Mounting......................................................................................Right Side Facing Manifold
Weight........................................................13 lbs. 4 oz........................(6.0 kg)
Crankcase Oil Capacity.............................8.1 .oz. ............................(0.24 liter)
Volumetric Efciency @ 1750 RPM......................................................0.95
Volumetric Efciency @ 3450 RPM......................................................0.87
Mechanical Efciency @ 3450 RPM ....................................................0.86
*Positive inlet pressure required
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
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. Thedesiredpressureisachievedbyselecting
the correct nozzle size that corresponds with the
pump GPM.
P227A-5100
9
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
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.
Specications
Model P230A-5100
U.S. (Metric)
1750 RPM *
Ratings......................................................1.1 GPM @ 2000 PSI .....(4.1 LPM @ 140 bar)
3450 RPM *
Ratings...................................................... 2.1 GPM @ 2000 PSI .....(8.1 LPM @ 140 bar)
Inlet Pressure............................................ 14 to 145 PSI..................(1 to 10 bar)
RPM...................................................................................................Up to 3450 RPM
Plunger Diameter......................................0.71”................................18mm
Stroke .......................................................0.13”................................3.4mm
Temperature of Pumped Fluids................. Up to 86oF......................(30oC)
Inlet Ports ..........................................................................................(2) 1/2” BSP
Discharge Ports.................................................................................(2) 3/8” BSP
Shaft Rotation ......................................................................................Top of Pulley Towards Fluid End
Crankshaft Diameter..........................................................................24mm
Key Width ..........................................................................................8mm
Shaft Mounting...................................................................................Right Side Facing Manifold
Weight....................................................... 13 lbs. 4 oz. ....................(6.0 kg)
Crankcase Oil Capacity............................ 8.1 .oz. ..........................(0.24 liter)
Volumetric Efciency @ 1750 RPM...................................................0.94
Volumetric Efciency @ 3450 RPM...................................................0.87
Mechanical Efciency @ 3450 RPM .................................................0.86
*Positive inlet pressure required
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
PULLEY INFORMATION
Pulleyselectionandpumpspeedarebasedona1725
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
10
Exploded View - P200A-5100 Series
26A
26A