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 03/17
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
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

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

Max.
Flow
Max.
Flow
Nominal/
Intermittent
Pressure
Nominal/
Intermittent
Pressure
Max.
Speed
Plunger
Diameter
Plunger
Diameter
Stroke Stroke Power
Req’d
Power
Req’d
Model GPM l/min PSI bar RPM in mm in mm BHP kW
P230 1.1 4.2 2000 140 1750 0.71 18 0.13 3.4 1.5 1.1
P217 1.85 7.0 2000 140 1750 0.71 18 0.22 5.5 2.5 1.9
P230 2.1 8.1 2000 140 3450* 0.71 18 0.13 3.4 2.9 2.2
P227 2.1 8.0 2000 140 1750 0.71 18 0.25 6.3 2.9 2.2
P221 2.3 8.9 2000 140 1750 0.71 18 0.28 7.0 3.3 2.4
P217 3.6 13.8 2000 140 3450* 0.71 18 0.22 5.5 5.0 3.7
P218 3.4 12.8 2000 140 1750 0.71 18 0.39 10.0 4.7 3.5
P227 3.8 14.4 2000 140 3450* 0.71 18 0.25 6.3 5.2 3.9
P219 4.2 15.9 2000 140 1750 0.71 18 0.49 12.4 5.8 4.3
P221 4.6 17.6 2000 140 3450* 0.71 18 0.28 7.0 6.5 4.9
P220 4.7 17.6 2000 140 1750 0.71 18 0.56 14.1 6.5 4.9
*Positive inlet pressure required- Make sure that suction pulsation is sufciently dampened-water column reso-
nance must be avoided.
 U.S. Metric
Max. Temperature of Pumped Fluids ..................... 86 °F .......................................................................30 °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
Exploded View - P200A-5100 Series
26A
26A

5
ITEMPART 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
16F 07023 O-Ring 3
17 08442 Wrist Pin 3
19 08356 Oil Seal 3
20 08444A-0100 Seal Retainer, 316 S.S. 3
21 08443 O-Ring (-5100) 3
ITEM PART NO. DESCRIPTION QTY.
21 08443-0001 O-Ring,
Viton (-5111/-5121) 3
21 06815 O-Ring (-5123) 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/-5123) 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,
(P221/P227/P230) 6
28 07491-0100 Valve Plate,
(P217/P218/P219/P220) 6
29 07906-0100 Valve Spring 6
30 07907 Valve Spring Retainer 6
31 07853 O-Ring (-5100) 6
31 07853-0001 O-Ring (-5111/-5121) 6
31 06817 O-Ring (-5123) 6
32 07928-0100 Plug 6
33 07913 O-Ring (-5100) 6
33 07913-0001 O-Ring (-5111/-5121) 6
33 06818 O-Ring (-5123) 6
34 08316-0100 Hex Head Cap Screw 8
36 12138 Plug, 3/8” BSP 1
36A 07109-0400 Plug, 1/2” BSP 1
P200A-5100 SERIES PARTS LIST

6
P200A-5100 SERIES REPAIR KITS
Plunger Packing Kits
P218A/P219A/P220A-5100
Part - #09602
Item Part # Description Qty.
21 08443 O-Ring 3
23 08477 Grooved Seal 3
23A 08087 Grooved Seal Ring 3
23B 06163 Drip Shield 3
24 07904 Pressure Ring 3
P217A/P221A/P227A/P230A-5100
Part - #09756
Item Part# Description Qty.
21 08443 O-Ring 3
23 06704 Grooved Seal 3
23A 08087 Grooved Seal Ring 3
23B 06163 Drip Shield 3
24 07904 Pressure Ring 3
P218A/P219A/P220A-5111
Part - #09602-0011
Item Part# Description Qty.
21 08443-0001 O-Ring 3
23 08087-0010 Grooved Seal, Viton 6
23B 06163 Drip Shield 3
24 07904 Pressure Ring 3
P218A/P219A/P220A-5121
Part - #09602-0021
Item Part# Description Qty.
21 08443-0001 O-Ring 3
23 08087-0020 Grooved Seal, Teon 6
23B 06163 Drip Shield 3
24 07904 Pressure Ring 3
P218A/P219A/P220A-5123
Part - #09602-0023
Item Part# Description Qty.
21 06815 O-Ring 3
23 08087-0020 Grooved Seal, Teon 6
23B 06163 Drip Shield 3
24 07904 Pressure Ring 3
Oil Seal Kit
Part# 09144
Item Part # Description Qty.
19 08356 Oil Seal 3
Valve Assembly Kits
P217/P218/P219/P220-5100
Part # 09139
Item Part # Description Qty.
27 07849-0100 Valve Seat 6
28 07491-0100 Valve Plate 6
29 07906-0100 Valve Spring 6
30 07907 Valve Retainer 6
31 07853 O-Ring 6
33 07913 O-Ring 6
P221/P227/P230-5100
Part # 09139A-5100
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
P217/P218/P219/P220-5111/-5121
Part # 09139-0011
Item Part # Description Qty.
27 07849-0100 Valve Seat 6
28 07491-0100 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
P221/P227/P230-5111/-5121
Part # 09139A-0011
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
P217/P218/P219/P220-5123
Part # 09139-0023
Item Part # Description Qty.
27 07849-0100 Valve Seat 6
28 07491-0100 Valve Plate 6
29 07906-0100 Valve Spring 6
30 07907 Valve Retainer 6
31 06817 O-Ring 6
33 06818 O-Ring 6
P221/P227/P230-5123
Part # 09139A-0023
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 06817 O-Ring 6
33 06818 O-Ring 6

7
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.
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 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.
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!

8
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). 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
1
2
3
4
5
6
7
8
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 106 inch-pounds (12 Nm) in a
crossing pattern (see below).
6) Re-install the six o-rings (31) and the six valve assemblies
(27-30). Now replace the six valve plugs with o-rings (32 and
33) and tighten securely with a 22mm socket wrench to 55
foot-pounds
(75 Nm).
7) Fill crankcase with 8.1 ounces (0.24 L) of oil.

9
P200A-5100 SERIES TORQUE SPECIFICATIONS
Position Item# Description Torque Amount
3A 07190-0100 Drain Plug & Gasket 22 ft.-lbs. (30 Nm)
5 08185-0100 Oil Drain Plug with Seal 22 ft.-lbs. (30 Nm)
6 07188-0100 Screw, 316 S.S. 88 in.-lbs. (10 Nm)
10 07225-0100 Screw 88 in.-lbs. (10 Nm)
16C 08456-0100 Tension Screw, Plunger 200 in.-lbs. (22.5 Nm)
32 07928-0100 Valve Plug 55 ft.-lbs. (75 Nm)
34 08316-0100 Hex Head Cap Screw, Valve Casing 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 X X
Seal Spare Parts (1 kit/pump) X
(See page 6 for kit list)
Oil Seal Kit (1 kit/pump) X
(See page 6 for kit lit)
Valve Spare Parts (1 kit/pump) X
(See page 6 for kit list)
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”)

10
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

11
P200A-5100 DIMENSIONS - INCHES (mm)

GIANT INDUSTRIES LIMITED WARRANTY
Giant Industries, Inc. pumps and accessories are warranted by the manufacturer to be free from defects
in workmanship and material as follows:
1. For portable pressure washers and 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 workman-
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 [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 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.
03/17 P200A-5100.indd
, 900 N. Westwood Ave., Toledo, Ohio 43607
Phone [phone], Fax [phone], www.giantpumps.com
 Copyright 2017 Giant Industries, Inc.