Giant P200a-5100 series repair and User manual

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

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.

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

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

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

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

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

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

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

Exploded View - P200A-5100 Series

26A

ITEM PART NO. DESCRIPTION QTY.

1 08300A Crankcase, Anodized 1

2 08301 Dipstick, Except P217-5100 1

2 08480 Dipstick, P217-5100 Only 1

3 08302A Crankcase Cover, Anodized 1

3A 07190-0100 Drain Plug & Gasket 1

4 08005 O-Ring 1

5 08185-0100 Oil Drain Plug with seal 1

6 07188-0100 Screw, 316 S.S. 4

6A 07223-0100 Spring Washer, 316 S.S. 4

7 08303 Bearing Cover 2

8 08490 Sight Glass 1

9 08492 O-Ring 1

10 07225-0100 Screw 8

10A 07223-0100 Spring Washer 8

11 01166 Radial Shaft Seal 1

12A 08020 Ball Bearing 1

12B 01020 Ball Bearing 1

13 08465 Crankshaft (P217A-5100) 1

13 08440 Crankshaft (P218A-5100) 1

13 08466 Crankshaft (P219A-5100) 1

13 08467 Crankshaft (P220A-5100) 1

13 12258 Crankshaft (P221A-5100) 1

13 06547 Crankshaft (P227A-5100) 1

13 06694 Crankshaft (P230A-5100) 1

14 06207 Fitting Key 1

15 08333 Connecting Rod 3

16 08469-0100 Plunger Assembly,

Except P230-5100 3

16A 08468-0100 Plunger Base, 316 S.S. 3

16B 08455 Plunger 3

16C 08456-0100 Tension Screw, 316 S.S. 3

16D 07204-0100 Crush Washer, 316 S.S. 3

16E 07203 Support Ring 3

ITEM PART NO. DESCRIPTION QTY.

16F 07023 O-Ring 3

17 08442 Wrist Pin 3

19 08356-0010 Oil Seal 3

20 08444A-0100 Seal Retainer, 316 S.S. 3

21 08443 O-Ring (-5100) 3

21 12260-0001 O-Ring, Viton (-5111/-5121) 3

23 08477 Grooved Seal

(P218/P219/P220-5100) 3

23 08087-0010 Grooved Seal, Viton

(P218/P219/P220-5111) 6

23 06704 Grooved Seal

(P217/P221/P227/P230-5100) 3

23 08087-0020 Grooved Seal, Teon (-5121) 6

23A 08087 Grooved Seal Ring, Brown (-5100) 3

23B 06163 Drip Shield 3

24 07904 Pressure Ring 3

25 08445-0100 Weep Return Ring, 316 S.S. 3

26 06582-5000 Valve Casing 1

26A 07946-0100 Valve Assembly 6

27 07849-0100 Valve Seat 6

28 06809 Valve Plate 6

29 07906-0100 Valve Spring 6

30 07907 Valve Spring Retainer 6

30A 06824 Spacer Ring, P230-5100 Only 3

31 07853 O-Ring (-5100) 6

31 07853-0001 O-Ring (-5111/-5121) 6

32 07928-0100 Plug 6

33 07913 O-Ring (-5100) 6

33 07913-0001 O-Ring (-5111/-5121) 6

34 08316-0100 Hex Head Cap Screw 8

36 12138 Plug, 3/8” 1

36A 07109-0400 Plug, 1/2” 1

P200A-5100 SERIES PARTS LIST

P200A-5100 SERIES REPAIR KITS

Plunger Packing Kits

Part#09602 - P218A/P219A/P220A-5100

Item Part # Description Qty.

23 08477 Grooved Seal 3

23A 08087 Grooved Seal Ring 3

23B 06163 Drip Shield 3

24 07904 Pressure Ring 3

Part#09602-0011-P218A/P219A/220A-5111

Item Part# Description Qty.

23 08087-0010 Grooved Seal, Viton 6

23B 06163 Drip Shield 3

24 07904 Pressure Ring 3

Part#09602-0021-P218A/P219A/P220A-5121

Item Part# Description Qty.

23 08087-0020 Grooved Seal, Teon 6

23B 06163 Drip Shield 3

24 07904 Pressure Ring 3

Part#09756-P217A/P221A/P227A/230A-5100

Item Part# Description Qty.

23 06704 Grooved Seal 3

23A 08087 Grooved Seal Ring 3

23B 06163 Drip Shield 3

24 07904 Pressure Ring 3

Valve Assembly Kit

Part # 09139-0011 - For -5111/-5121

Item Part # Description Qty.

27 07849-0100 Valve Seat 6

28 06809 Valve Plate 6

29 07906-0100 Valve Spring 6

30 07907 Valve Retainer 6

31 07853-0001 O-Ring 6

33 07913-0001 O-Ring 6

Oil Seal Kit

Part# 09144

Item Part # Description Qty.

19 08356-0010 Oil Seal 3

Valve Assembly Kit

Part # 09139 - For -5100 Series

Item Part # Description Qty.

27 07849-0100 Valve Seat 6

28 06809 Valve Plate 6

29 07906-0100 Valve Spring 6

30 07907 Valve Retainer 6

31 07853 O-Ring 6

33 07913 O-Ring 6

REPAIR INSTRUCTION - P200A-5100 SERIES

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 dam-

aged.

2. Using a needle nose pliers,

remove the inlet and dis-

charge valve assemblies

(26A), for P230-5100 only,

remove spacer (30A), 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) and drip shield (23B)

from the seal case (20).

Inspect all parts, including

o-ring (21) for wear and

replace as necessary.

8. Check surfaces of plunger

pipe (16B). A damaged

surface will cause acceler-

ated 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

prying loose with a at

screwdriver. Take care not

to make contact with the

plunger.

4. Apply one drop of Loctite

243 to the valve plugs (32)

and tighten to 33 ft.-lbs.

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.

Disassembly sequence of the back end of the P200A-5100 series pump.

1) Before you begin, drain the oil from the crankcase.

2) Remove the crankcase cover (3) and o-ring (4) from the crankcase (1). To remove the crank-

shaft (13), remove the bearing cover (7) and sight glass (8). Using a rubber mallet, remove the

crankshaft axially through the connecting rods by tapping on the end of the shaft. Be careful not

to bend or damage the connecting rods during crankshaft removal.

3) If the bearings (12A and 12B) and radial shaft seal (11) are still in the crankcase, remove them.

Inspect both bearings and seal for wear and replace if necessary.

4) Remove the connecting rod (15) and plunger assembly(16). Remove the wrist pin (17) if neces-

sary. Check the plunger bore in the crankcase for wear. Inspect parts and replace as neces-

sary.

5) Should you nd it necessary to service the plunger assembly (16) you can do so by removing

the tension screw (16C). Replace crush washer (16D). NOTE: Carefully atten crush washer

prior to replacing it. NOTE: Place side with line in the middle on the ceramic surface and

use a hand press to cursh the washer prior to installing the tension screw. Inspect all

parts and replace as necessary.

Reassembly sequence of the P200A-5100 series pump

1) Reassemble plunger asembly (16) (apply a drop of Loctite to the tension screw (16C) threads)

and the connecting rod (15) with wrist pin (17). Place assemblies in crankcase (1). Install crank-

shaft through connecting rods again being careful not to bend or otherwise damage the con-

necting rods.

2) Replace left and right side bearings (12A and 12B) if they were removed from the crankshaft.

Be certain the bearings are pressed all the way onto the shaft and completely into the crank-

case. Replace radial shaft seal (11), bearing cover (7), sight glass (8), and crankcase cover (3)

with its o-ring (4).

3) If oil seals (19) were removed, replace with seal lip towards crankcase. Lubricate seal before

replacing.

4) Replace seal case (20) with o-rings (21) over plungers. Generously lubricate o-rings and oil seal

REPAIR INSTRUCTION - P200A-5100 SERIES

before reassembly. Replace drip shield (23B) and v-sleeve

(23A) over plungers (16)..

5) Generously lubricate v-sleeve (23) and assemble into valve

casing (26). Assemble weep return ring (25) and pressure

ring (24) over plungers (16). Slide valve casing over plung-

ers and seat rmly. Replace the eight socket head cap

screws (34) and tighten to 105 inch-pounds in a crossing

pattern (see below).

6) Re-install the six o-rings (31) and the six valve assemblies

(27-30) and spacer ring (30A), P230-5100 only. Now replace

the six valve plugs with o-rings (32 and 33) and tighten se-

curely with a 22mm socket wrench to 33 foot-pounds.

7) Fill crankcase with 8.1 ounces of oil.

P200A-5100 SERIES TORQUE SPECIFICATIONS

Position Item# Description Torque Amount (ft.-lbs) Nm

16C 08456-0100 Tension Screw, Plunger 220 (in.-lbs.) 24.9 Nm

32 07928-0100 Valve Plug 33 (ft.-lbs.) 44.7 Nm

34 08316-0100 Hex Head Cap Screw, Valve Casing 105 (in.-lbs.) 11.9 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 X X

Seal Spare Parts (1 kit/pump) X

(See page 11 for kit list)

Oil Seal Kit (1 kit/pump) X

(See page 11 for kit lit)

Valve Spare Parts (1 kit/pump) X

(See page 11 for kit list)

PUMP SYSTEM MALFUNCTION

MALFUNCTION CAUSE REMEDY

The Pressure and/ Worn packing seals Replace packing seals

or the Delivery Broken valve spring Replace spring

Drops Belt slippage Tighten or Replace belt

Worn or Damaged nozzle Replace nozzle

Fouled discharge valve Clean valve assembly

Fouled inlet strainer Clean strainer

Worn or Damaged hose Repair/Replace hose

Worn or Plugged relief valve on pump Clean, Reset, and Replace worn parts

Cavitation Check suction lines on inlet of

pump for restrictions

Unloader Check for proper operation

Water in crankcase High humidity Reduce oil change interval

Worn seals Replace seals

Noisy Operation Worn bearings Replace bearings, Rell crankcase

oil with recommended lubricant

Cavitation Check inlet lines for restrictions

and/or proper sizing

Rough/Pulsating Worn packing Replace packing

Operation with Inlet restriction Check system for stoppage, air

Pressure Drop leaks, correctly sized inlet

plumbing to pump

Accumulator pressure Recharge/Replace accumulator

Unloader Check for proper operation

Cavitation Check inlet lines for restrictions

and/or proper size

Pressure Drop at Gun Restricted discharge plumbing Re-size discharge plumbing to

ow rate of pump

Excessive Worn plungers Replace plungers

Leakage Worn packing/seals Adjust or Replace packing seals

Excessive vacuum Reduce suction vacuum

Cracked plungers Replace plungers

Inlet pressure too high Reduce inlet pressure

High Crankcase Wrong Grade of oil Giant oil is recommended

Temperature Improper amount of oil in crankcase Adjust oil level to proper amount

P200A-5100 DIMENSIONS - INCHES (mm)

Pump Mounting Selection Guide

Bushings

07174 - 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-1.0”XH=1.812”)

01161 - Plated Steel Channel Rails (L=5.75”x W-1.0”XH=2.50”)

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

productsreturned freight prepaidtoGiant Industries whichare deemed to bedefective due toworkman-

ship 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 consid-

eration. 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 IN-

DIRECTLY ARISING FROM THE SALE OR USE OF THIS PRODUCT.

THE LIMITED WARRANTY SET FORTH HEREIN IS IN LIEU OF ALL OTHER WARRANTIES OR REP-

RESENTATION, 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.

10/13 P200A-5100.indd

GIANT INDUSTRIES, INC., 900 N. Westwood Ave., Toledo, Ohio 43607

Phone (419) 531-4600, Fax (419) 531-6836, www.giantpumps.com

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