Giant P205 Repair and User manual

Contents:
Installation Instructions: page 2
Pump Specifications: pages 3-5
Exploded View: page 6
Parts List: page 7
Kits & Torque Specifications:page 7
Repair Instructions: pages 8-9
Trouble Shooting: page 10
Dimensions: back page
Warranty Information: back page
TM
Triplex Ceramic
Plunger Pump
Operating Instructions/
Repair and Service
Manual
Models
P205/206/208

2
INSTALLATION INSTRUCTIONS
4. Use of a dampener is necessary to minimize
pulsation at drive elements, plumbing, connec-
tions, 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
following a few guidelines available upon
request from Giant Industries, Inc. Required
horsepower for system operation can be ob-
tained from the chart on page 3.
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. Cavitation will
result in severe damage. Always remember to
check that all plumbing valves are open and that
pumped media can flow 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
pressure, volume, or RPM. A pressure relief
device must be installed in the discharge of the
system.
3. Acids, alkalines, or abrasive fluids 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
crankcase so that oil level is between the two
lines on the oil dipstick. DO NOT OVERFILL.
Use Giant oil
Crankcase oil should be changed after the
first 50 hours of operation, then at regular
intervals of 500 hours or less depending on
operating 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 installa-
tion. If you have unique requirements, please
contact Giant Industries, Inc. or your local
distributor for assistance.
1. The pump should be installed flat 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
flow rate of the pump with no unnecessary
restrictions that can cause cavitation. Teflon
tape should be used to seal all joints. If pumps
are to be operated at temperatures in excess of
1600F, 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 flow rate to
prevent line pressure loss to the work area. It is
essential 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,rememberthathighpressureoperationinapumpsystemhasmanyadvantages. But,ifitisusedcarelessly
and without regard to its potential hazard, it can cause serious injury.

HORSEPOWER RATINGS:
The rating shown are the power
requirements 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 specified when selecting an
electricmotor as the power source.
To compute specific pump horse
power requirements, use the
following formula:
HP = (GPM X PSI) / 1450
3
Specifications
Model P205
1750 RPM+
Ratings (Continuous).................................................................................. 0.5 GPM @ 2000 PSI
Ratings (Intermittent) ................................................................................. 0.5 GPM @ 2500 PSI*
3450 RPM+
Ratings (Continuous).................................................................................. 0.9 GPM @ 2000 PSI
Ratings (Intermittent) ................................................................................. 0.9 GPM @ 2500 PSI*
Inlet Pressure .............................................................................................. Up to 90 PSI
RPM............................................................................................................ Up to 1750 RPM
Plunger Diameter........................................................................................ 12mm
Stroke.......................................................................................................... 3.4mm
Temperature of Pumped Fluids .................................................................. Up to 160oF
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......................................................................................................... 11 lbs. 11oz.
Crankcase Oil Capacity .............................................................................. 7.5 fl.oz.
Extended Crankcase Oil Capacity .............................................................. 9.0 fl.oz.
Volumetric Efficiency @ 3450 RPM.......................................................... 0.88
Mechanical Efficiency @ 3450 RPM......................................................... 0.86
+Positive inlet pressure required
Consult the factory for special requirements that must be met if the pump is
to operate beyond one or more of the limits specified above.
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 fill and the oil drain plugs, also. Refer to the repair instructions as
necessary for the proper assembly sequence.
SPECIALNOTE:
The theoretical gallons per revolution
(gal/rev) is 0.0002899.
To find specific outputs at various RPM,
use the formula: GPM =0.0002899xRPM
*intermittent duty
P205 HORSEPOWER REQUIREMENTS
RPM GPM 1000 PSI 1500 PSI 2000 PSI 2500 PSI*
500 0.13 0.1 0.1 0.2 0.2
1000 0.26 0.2 0.3 0.4 0.4
1750 0.46 0.3 0.5 0.6 0.8
3000 0.80 0.6 0.8 1.1 1.4
3200 0.83 0.6 0.9 1.1 1.4
3450 0.90 0.6 0.9 1.2 1.6

P206 HORSEPOWER REQUIREMENTS
RPM GPM 1000 PSI 1500 PSI 2000 PSI 2500 PSI*
250 0.11 0.1 0.1 0.2 0.2
500 0.21 0.1 0.2 0.3 0.4
1000 0.43 0.3 0.4 0.6 0.7
1750 0.76 0.5 0.8 1.0 1.3
3000 1.30 0.9 1.3 1.8 2.2
3200 1.40 1.0 1.4 1.9 2.4
3450 1.50 1.0 1.6 2.1 2.6
4
Specifications
Model P206
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 fill and the oil
drain plugs, also. Refer to the repair instructions as necessary for
the proper assembly sequence. HORSEPOWER RATINGS:
The rating shown are the power
requirements 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 specified when selecting an
electric motor as the power source.
To compute specific pump horse
power requirements, use the
following formula:
HP = (GPM X PSI) / 1450
Consult the factory for special requirements that must be met if the pump is
to operate beyond one or more of the limits specified above.
1750 RPM+
Ratings (Continuous).................................................................................. 0.8 GPM @ 2000 PSI
Ratings (Intermittent) .................................................................................0.8 GPM @ 2500 PSI*
3450 RPM+
Ratings (Continuous).................................................................................. 1.5 GPM @ 2000 PSI
Ratings (Intermittent) .................................................................................1.5 GPM @ 2500 PSI*
Inlet Pressure .............................................................................................. up to 140 PSI
Plunger Diameter........................................................................................ 12mm
Stroke.......................................................................................................... 5.5mm
Temperature of Pumped Fluids .................................................................. Up to 160o F
Inlet Ports.................................................................................................... (2) 1/2" BSP
Discharge Ports........................................................................................... (2) 3/8" BSP
Shaft Rotation ................................................................................Top of Pulley Towards Fluid End
Crankshaft Diameter................................................................................... Solid, 24mm
Key Width...................................................................................................8mm
Shaft Mounting ...........................................................................................Right Side Facing Manifold
Weight.........................................................................................................11 lbs. 11oz.
Crankcase Oil Capacity .............................................................................. 7.5 fl.oz.
Extended Crankcase Oil Capacity .............................................................. 9.0 fl.oz.
Volumetric Efficiency @ 1750 RPM.......................................................... 0.94
Volumetric Efficiency @ 3450 RPM.......................................................... 0.88
Mechanical Efficiency @ 3450 RPM......................................................... 0.86
+Positive inlet pressure required
*Intermittent duty only

P208 HORSEPOWER REQUIREMENTS
RPM GPM 1000 PSI 1500 PSI 2000 PSI 2500 PSI*
250 0.14 0.1 0.1 0.2 0.2
500 0.29 0.2 0.3 0.4 0.5
1000 0.57 0.4 0.6 0.8 1.0
1750 1.00 0.7 1.0 1.4 1.7
3000 1.60 1.1 1.7 2.2 2.8
3200 1.80 1.2 1.9 2.5 3.1
3450 1.90 1.3 2.0 2.6 3.3
5
Specifications
Model P208
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 fill and the oil
drain plugs, also. Refer to the repair instructions as necessary for
the proper assembly sequence.
HORSEPOWER RATINGS:
The rating shown are the power
requirements 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 specified when selecting an
electric motor as the power source.
To compute specific pump horse
power requirements, use the
following formula:
HP = (GPM X PSI) / 1450
Consult the factory for special requirements that must be met if the pump is
to operate beyond one or more of the limits specified above.
1750 RPM
Ratings (Continuous).................................................................................. 1.0 GPM @ 2000 PSI
Ratings (Intermittent) .................................................................................1.0 GPM @ 2500 PSI*
3450 RPM
Ratings (Continuous).................................................................................. 1.9 GPM @ 2000 PSI
Ratings (Intermittent) .................................................................................1.9 GPM @ 2500 PSI*
Inlet Pressure .............................................................................................. up to 140 PSI
Plunger Diameter........................................................................................ 12mm
Stroke.......................................................................................................... 7mm
Temperature of Pumped Fluids .................................................................. Up to 160o F
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.........................................................................................................11 lbs. 11oz.
Crankcase Oil Capacity .............................................................................. 7.5 fl.oz.
Extended Crankcase Oil Capacity .............................................................. 9.0 fl.oz.
Volumetric Efficiency @ 1750 RPM.......................................................... 0.94
Volumetric Efficiency @ 3450 RPM.......................................................... 0.88
Mechanical Efficiency @ 3450 RPM......................................................... 0.86
*Intermittent duty only

6
Exploded View - P205/206/208

Position Item# Description Torque Amount
32 07928 Valve Plug 33 or 59* (ft.-lbs.)
34 08316 Hex Head Cap Screw, Valve Casing 105 (in.-lbs.)
7
ITEM PART NO. DESCRIPTION QTY.
16 06641 Plunger, Complete, 12mm 3
17 08442 Wrist Pin 3
19 08356-0010 Oil Seal 3
20 06645 Seal Case 3
21 08443 O-Ring 3
23 07391 V-Sleeve 3
23A 08598 V-Sleeve, Weep 3
24 07392 Support Ring 3
25 06646 Weep Return Ring 3
26 06647 Valve Casing 1
27 07849 Valve Seat 6
28 07491 Valve Plate 6
29 07906 Valve Spring 6
30 07907 Valve Spring Retainer 6
31 07853 O-Ring 6
32 07928 Valve Plug 6
32X 07946 Valve Assembly Complete 6
33 07913 O-Ring 6
34 08316 Hex Head Cap Screw 8
38 13338 Plug, 3/8" BSP 1
38A 07661 Seal 1
39 07109 Plug, 1/2" BSP 1
39A 08486 Copper Seal Ring 1
P205/206/208 PARTS LIST
ITEM PART NO. DESCRIPTION QTY.
1 08300 Crankcase 1
2 08301 Dipstick and Gasket, Black 1
3 08302 Crankcase Cover, Short 1
3 08302-L Crancase Cover, Long 1
3A 07190 Drain Plug 1
3B 13262 Gasket for drain plug 1
4 08005 O-Ring 1
5 06273 Oil Drain Plug with Gasket 1
5A 08192 Gasket 1
6 07188 Screw, Short Cover 4
6A 01176-2 Spring Washer 4
7 08303 Bearing Cover I 2
8 08490 Sight Glass 1
9 08492 O-Ring 1
10 07225 Screw with Lock Washer 8
11 01166 Radial Shaft Seal 1
12A 08020 Ball Bearing 1
12B 01020 Ball Bearing 1
13 06694 Crankshaft (P205) 1
13 08465 Crankshaft (P206) 1
13 12258 Crankshaft (P208) 1
14 06207 Woodruf Key 1
15 08333 Connecting Rod 3
P205/206/208 REPAIR KITS
Plunger Packing Kit
Part # 09527
Item # Part # Description Qty.
23 07391 V-Sleeve, weep 3
23A 08598 V-Sleeve 3
24 07392 Support Ring 3
Oil Seal Kit
Part # 09144
Item # Part # Description Qty.
19 08356-0010 Oil Seal 3
P205/206/208 TORQUE SPECIFICATIONS
Valve Assembly Kit
Part # 09116
Item # Part # Description Qty.
32X 07946 Valve Assembly Complete 6
31 07853 O-Ring 6

8
NOTE: Always take time to lubricate all metal and nonmetal parts with a light film of oil before reassembly.
This step will ensure proper fit, at the same time protecting the pump nonmetal parts (i.e., the elastomers) from cutting
and scoring.
1. With a 22mm socket
wrench, remove the (3)
discharge valve plugs and
(3) inlet valve plugs (32)
Inspect the o-ring (33) for
wear and replace if dam-
aged.
2. Using a needle nose pliers,
remove the inlet and
discharge valve assemblies
(32X).
3. By inserting a small screw
driver between the valve
seat (27) and the valve
spring retainer (30), the
valve assembly can be
separated.
7. Remove the weep return
ring (25), pressure ring
(24), and v-sleeve (23)
from the valve casing (26).
Remove the weep v-sleeve
(23A) from the seal case
(20).Inspect all parts,
including o-ring (21) for
wear and replace as
necessary.
8. Check surfaces of plunger
(16). A damaged surface
will cause accelerated
wear on the seals. Depos-
its 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
first removing the crank-
shaft (13), connecting rod
(15), and plunger assem-
bly (16) from the gear end.
Then the oil seals can be
pushed out from the rear.
Please contact Giant for
details.
4. Remove the o-ring (31).
Inspect all parts for wear
and replace as necessary.
For pumps manufactured
prior to 5/97, tighten plugs
(32) to 33 ft-lbs. otherwise,
apply one drop of Loctite
243 to the valve plugs (32)
and tighten to 59 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.
REPAIR INSTRUCTIONS - P205/206/208 PUMPS

9
Reassembly sequence of the P205/206/208 PUMPS
1) If oil seals (19) were removed, replace with seal lip towards crankcase. Lubricate seals before replacing.
Contact Giant for assistance with the reassembly of the gear end.
2) Replace seal case (20) with o-rings (21) over plungers. Generously lubricate o-rings and oil seal before
reassembly. Replace weep v-sleeve (23A) over plungers (16)..
3) Generously lubricate v-sleeve (23). Assemble v-sleeves (23) into valve casing (#26). Assemble weep
return ring (25) and pressure ring (24) over plungers (16). Slide valve casing over plungers and seat
firmly. Replace the eight socket head cap screws (34) and tighten to 105 inch-pounds in a crossing
pattern.
4) Replace the six o-rings (31) and the six valve assemblies (32X). Now replace the six valve plug o-rings
(33). Apply one drop of Loctite 243 to the valve plugs (32) and tighten to 59 ft.-lbs.
REPAIR INSTRUCTIONS - P205/206/208 PUMPS
NOTE: Contact Giant Industries for Service School Information. Phone: [phone]
For maintenance of the gear end of your pump contact Giant Industries or your local distributor.
Phone: [phone]
NOTE: If there are
deposits of any kind (i.e.,
lime deposits) in the valve
casing, be certain that the
weep holes in the weep
return ring (25) and valve
casing (26) have not been
plugged.
10. If the ceramic plunger pipe
(16B) is damaged, replace
entire plunger assembly by
removing crankshaft (13).
Contact Giant for further
details.

REMEDY
Replace packing seals
Replace spring
Tighten or Replace belt
Replace nozzle
Clean valve assembly
Clean strainer
Repair/Replace hose
Clean, Reset, and Replace worn parts
Check suction lines on inlet of
pump for restrictions
Check for proper operation
Reduce oil change interval
Replace seals
Replace bearings, Refill crankcase
oil with recommended lubricant
Check inlet lines for restrictions
and/or proper sizing
Replace packing
Check system for stoppage, air
leaks, correctly sized inlet
plumbing to pump
Recharge/Replace accumulator
Check for proper operation
Check inlet lines for restrictions
and/or proper size
Re-size discharge plumbing to
flow rate of pump
Replace plungers
Adjust or Replace packing seals
Reduce suction vacuum
Replace plungers
Reduce inlet pressure
Giant oil is recommended
Adjust oil level to proper amount
PUMP SYSTEM MALFUNCTION
MALFUNCTION
The Pressure and/
or the Delivery
Drops
Water in crankcase
Noisy Operation
Rough/Pulsating
Operation with
Pressure Drop
Pressure Drop at
Gun
Excessive Leakage
High Crankcase
Temperature
CAUSE
Worn packing seals
Broken valve spring
Belt slippage
Worn or Damaged nozzle
Fouled discharge valve
Fouled inlet strainer
Worn or Damaged hose
Worn or Plugged relief valve on pump
Cavitation
Unloader
High humidity
Worn seals
Worn bearings
Cavitation
Worn packing
Inlet restriction
Accumulator pressure
Unloader
Cavitation
Restricted discharge plumbing
Worn plungers
Worn packing/seals
Excessive vacuum
Cracked plungers
Inlet pressure too high
Wrong Grade of oil
Improper amount of oil in crankcase
10

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 self-serve 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 applica-
tions, are warranted for five 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 modifications made by the customer or third party.
6. The operation of pumps and or accessories exceeding the specifications 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 WAR-
RANTIES OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE AND ALL SUCH
WARRANTIES ARE HEREBY DISCLAIMED AND EXCLUDED BY THE MANUFACTURER.
P205/206/208 DIMENSIONS (inches)
GIANT INDUSTRIES, INC., 900 N. Westwood Ave., P.O. Box 3187, Toledo, Ohio 43607
PHONE [phone], FAX [phone], www.giantpumps.com
Ó Copyright 2001 Giant Industries, Inc. 05/01 P205/206/208.PM6