Triplex Ceramic
Plunger Pump
OperatingInstructions/
Repair and Service
Manual
Series
CP200
For Models:
CP218
CP220
CP230
Contents:
InstallationInstructions:
PumpSpecifications:
Exploded View:
page 2
pages 3-5
page 6
PartsList::
page 7
Recommended Spare
Kits & Torque Specifications: page 8
PumpMountingSelection
Guide:
page 8
pages 9-10
page 11
RepairInstructions:
TroubleShooting:
Preventative
Maintenance:
Dimensions:
WarrantyInformation:
page 11
back page
back page
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Specifications
Model CP218
Ratings ........................................................................................................ 1.4 GPM @ 2030 PSI
Inlet Pressure.............................................................................................. 14 to 140 PSI
RPM ........................................................................................................... Up to 750 RPM
Plunger Diameter........................................................................................ 18mm
Stroke.......................................................................................................... 10mm
Temperature of Pumped Fluids................................................................... -40oF to 160oF
Inlet Ports ................................................................................................... (2) 3/8" BSP
Discharge Ports .......................................................................................... (2) 3/8" BSP
Shaft Rotation ................................................................................ Top of PulleyTowards Fluid End
Crankshaft Diameter .................................................................................. 24mm
KeyWidth ................................................................................................... 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.
+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.
HORSEPOWER RATINGS:
The rating shown are the power
CP218 HORSEPOWER REQUIREMENTS
requirements for the pump. Gas
engine power outputs must be
approximately twice the pump
power requirements shown above.
RPM GPM 500 PSI 1000 PSI 1500 PSI 2030 PSI
200 0.4
300 0.6
400 0.7
500 0.9
600 1.1
750 1.4
0.1
0.2
0.2
0.3
0.4
0.5
0.3
0.4
0.5
0.6
0.8
1.0
0.4
0.6
0.7
0.9
1.1
1.4
0.6
0.8
1.0
1.3
1.5
2.0
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
3
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Specifications
Model CP220
Ratings ........................................................................................................ 1.9 GPM @ 2030 PSI
Inlet Pressure.............................................................................................. 14 to 140 PSI
RPM ........................................................................................................... Up to 750 RPM
Plunger Diameter........................................................................................ 18mm
Stroke.......................................................................................................... -40o to 160oF
Inlet Ports ................................................................................................... (2) 3/8" BSP
Discharge Ports .......................................................................................... (2) 3/8" BSP
Shaft Rotation ................................................................................ Top of Pulley Towards Fluid End
Crankshaft Diameter .................................................................................. 24mm
KeyWidth ................................................................................................... 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.
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.
HORSEPOWER RATINGS:
The rating shown are the power
requirements for the pump. Gas
CP220 HORSEPOWER REQUIREMENTS
engine power outputs must be
approximately twice the pump
power requirements shown above.
RPM GPM 500 PSI 1000 PSI 1500 PSI 2030 PSI
200 0.5
300 0.8
400 1.0
500 1.3
600 1.5
750 1.9
0.2
0.3
0.3
0.4
0.5
0.7
0.3
0.6
0.7
0.9
1.0
1.3
0.5
0.8
1.0
1.3
1.6
2.0
0.7
1.1
1.4
1.8
2.1
2.7
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
4
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Specifications
Model CP230
Ratings ........................................................................................................ 0.5 GPM @ 2030 PSI
Inlet Pressure.............................................................................................. 14 to 140 PSI
RPM ........................................................................................................... Up to 750 RPM
Plunger Diameter........................................................................................ 18mm
Stroke.......................................................................................................... 3.4mm
Temperature of Pumped Fluids................................................................... -40o to 160oF
Inlet Ports ................................................................................................... (2) 3/8" BSP
Discharge Ports .......................................................................................... (2) 3/8" BSP
Shaft Rotation ................................................................................ Top of Pulley Towards Fluid End
Crankshaft Diameter .................................................................................. 24mm
KeyWidth ................................................................................................... 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.
+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.
HORSEPOWER RATINGS:
The rating shown are the power
requirements for the pump. Gas
engine power outputs must be
approximately twice the pump
CP230 HORSEPOWER REQUIREMENTS
RPM GPM 500 PSI 1000 PSI 1500 PSI 2030 PSI
200 0.1
300 0.2
400 0.3
500 0.3
600 0.4
750 0.5
0.0
0.1
0.1
0.1
0.1
0.2
0.1
0.1
0.2
0.2
0.3
0.3
0.1
0.2
0.3
0.3
0.4
0.5
0.1
0.3
0.4
0.4
0.6
0.7
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
5
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Exploded View
CP200 Series
6
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Spare Parts
CP200 Series
ITEM PARTNO. DESCRIPTION
QTY.
ITEM PARTNO. DESCRIPTION
QTY.
1
08300
06773
08302
08302-L
07190
08005
06273
08192
07188
Crankcase
1
16C
16D
16D
16E
17
08456
07676
Tension Screw
CopperGasket
3
3
3
2
OilDipstickwithO-Ring
Crankcase Cover, Short
Crancase Cover, Long
Drain Plug & Gasket
O-Ring
1
3
1
07204-0100 Copper Gasket(CP230only)
3
1
06823
08442
07770
PlungerExtension(CP230only) 3
3A
4
1
Wrist Pin
O-Ring
3
3
3
3
3
3
3
3
3
1
6
6
6
6
3
6
6
6
6
8
1
1
18
5
OilDrainPlug
1
19
08356-0010 OilSeal
5A
6
Gasket
1
20
08444
06815
08087
Seal Case
Screw,CrankcaseCover
4
21
O-Ring
6A
7
07223-0100 Spring Washer
4
23
V-Sleeve,Weep
08303
08490
08492
07225
01166
08020
01020
08440
08467
06694
06207
08333
08469
08468
08455
Bearing Cover I
OilSightGlass
2
23A
24
08087-0020 V-Sleeve,Teflon
8
1
07904
08445
08446
07849
06809
06816
07907
06824
06817
07928
06825
06818
08316
13338
Pressure Ring
Weep Return Ring
ValveCasing
9
O-Ring
1
25
10
11
12A
12B
13
13
13
14
15
16
16A
16B
Screw with Lock Washer
RadialShaftSeal
BallBearing
8
26
1
27
ValveSeat
1
28
ValvePlate
BallBearing
1
29
ValveSpring
Crankshaft(CP218)
Crankshaft(CP220)
Crankshaft(CP230)
Woodruff Key
1
30
ValveSpringRetainer
SpacerRing(CP230only)
O-Ring
1
30A
31
1
1
32
ValvePlug
Connecting Rod
Plunger,Complete,18mm
Plunger Base
3
32X
33
Valve Assembly
O-Ring
3
3
34
HexHeadCapScrew
Plug, 3/8"BSP
PlungerPipe
3
38
7
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Repair Kits
CP200 Series
Oil Seal Kit
Plunger Packing Kit
Part # 09144
Part # 09554
Item # Part #
Description
Qty.
3
Item # Part #
Description
Qty.
3
19
08356-0010 Oil Seal
23
08087
V-Sleeve, weep
23A
24
08087-0020 V-Sleeve, brown
07904 Pressure Ring
3
3
Valve Assembly Kit
Part # 09556
Item # Part # Description
Qty.
6
6
6
6
27
28
29
30
31
07849 Valve Seat
06809 Valve Plate
06816 Valve Spring
07907 Valve Spring Retainer
06817 O-Ring
6
Pump Torque Specifications
CP200 Series
Position
Item#
08456
07928
08316
Description
Torque Amount
16C
32
Tension Screw, Plunger
Valve Plug
220 (in.-lbs.)
59 (ft.-lbs.)
105 (in.-lbs.)
34
Hex Head Cap Screw, Valve Casing
Pump Mounting Selection Guide
Bushings
01074 - 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”xW=1.00”xh=2.50”)
01161- Plated Steel Channel Rails
(L=5.75”xW=1.00”xH=2.50”)
8
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REPAIR INSTRUCTIONS - CP200 PUMPS
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
3. By inserting a small screw
driver between the valve
seat (27) and the valve
spring retainer (30), the
valve assembly can be
separated.
2. Using a needle nose pliers,
remove the inlet and
discharge valve assemblies
(27-31).
damaged.
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.
Remove the 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
prying loose with a flat
screwdriver. Take care
not to make contact with
the plunger.
7. Remove the weep return
ring (25), pressure ring
(24), and v-sleeve (23)
from the valve casing (26).
The spacer ring (30A) on
CP230 pumps may remain
inside the valve casing.
9
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REPAIR INSTRUCTIONS - CP200
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, remove
the plunger bolt (16C) and
plunger extension (16E-
CP230 only). Discard the
old plunger pipe (16B)
and copper gasket (16D).
Clean the old locktite from
the plunger bolt (16C) and
plunger base (16A).
Replace the plunger pipe,
plunger extension (16E-
(P230 only) and locktite the
plunger bolt and torque to
220 inch-pounds. Make
sure you use a new
gasket (16D) with the
plunger bolt.
Reassembly sequence of the CP200 pumps
1)
2)
If oil seals (19) were removed, replace with seal lip towards crankcase. Lubricate seals before replacing.
Replace seal case (20) with o-rings (21) over plungers. Generously lubricate o-rings and oil seal before
reassembly. Replace v-sleeve (23A) over plungers (16)..
3)
Generously lubricate v-sleeve (23). Assemble v-sleeves (22) into valve casing (#26). Make sure spacer
ring (30E - CP230 pumps only) is present in the valve casing. 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.
NOTE: Contact Giant Industries for Service School Information. Phone: (419)-531-4600
10
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PUMPSYSTEMMALFUNCTION
MALFUNCTION
CAUSE
REMEDY
The Pressure and/
or the Delivery
Drops
Worn packing seals
Broken valve spring
Belt slippage
Replace packing seals
Replace spring
Tighten or Replace belt
Replacenozzle
Worn or Damaged nozzle
Fouled discharge valve
Fouled inlet strainer
Worn or Damaged hose
Worn or Plugged relief valve on pump
Cavitation
Clean valve assembly
Cleanstrainer
Repair/Replace hose
Clean, Reset, and Replace worn parts
Check suction lines on inlet of
pump for restrictions
Unloader
Check for proper operation
Water in crankcase
Noisy Operation
High humidity
Worn seals
Reduce oil change interval
Replace seals
Worn bearings
oilwith
Cavitation
Replacebearings,Refillcrankcase
recommended lubricant
Check inlet lines for restrictions
and/or proper sizing
Rough/Pulsating
Operation with
Pressure Drop
Worn packing
Inlet restriction
Replacepacking
Check system for stoppage, air
leaks, correctly sized inlet
plumbing to pump
Accumulator pressure
Unloader
Cavitation
Recharge/Replaceaccumulator
Check for proper operation
Check inlet lines for restrictions
and/or proper size
Pump Pressure as
gun
Pressure
Restricted discharge plumbing
Re-size discharge plumbing to Drop at
flow rate of pump
Rated,
Excessive
Leakage
Worn plungers
Replace plungers
Worn packing/seals
Excessivevacuum
Cracked plungers
Inlet pressure too high
Adjust or Replace packing seals
Reduce suction vacuum
Replace plungers
Reduce inlet pressure
High Crankcase
Temperature
Wrong Grade of oil
Improper amount of oil in crankcase
Giant oil is recommended
Adjust oil level to proper amount
Preventative Maintenance Check-List & Recommended Spare Parts List
Check
Daily
Weekly
50hrs
Every
500 hrs
Every
1500 hrs
Every
3000 hrs
Oil Level/Quality
Oil Leaks
Water Leaks
Belts, Pulley
Plumbing
X
X
X
X
X
Recommended Spare Parts
Oil Change (1 Quart) p/n 1153
Seal Spare Parts (1 kit/pump)
(See page 8 for kit list)
Oil Seal Kit (1 kit/pump)
(See page 8 for kit lit)
X
X
X
X
Valve Spare Parts (1 kit/pump)
(See page 8 for kit list)
X
11
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CP200 SERIES DIMENSIONS (inches)
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 (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
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,EXPRESSORIMPLIED,INCLUDINGWITHOUTLIMITATIONANYWARRAN-
TIES OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE AND ALL SUCH
WARRANTIES ARE HEREBY DISCLAIMED AND EXCLUDED BY THE MANUFACTURER.
GIANT INDUSTRIES, INC., 900 N. Westwood Ave., P.O. Box 3187, Toledo, Ohio 43607
Ó Copyright 2002 Giant Industries, Inc.
4/02CP200.PM6
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