Triplex Ceramic
Plunger Pump
Operating Instructions/
Repair and Service
Manual
Series
P200A-3100/5100
Aluminum Bronze Models:
316 S.S. Models:
P217-3100
P218-3100
P219-3100
P220-3100
P217-5100
P218-5100
P219-5100
P220-5100
P221-3100
P227-3100
P230-3100
P221-5100
P227-5100
P230-5100
Stainless Steel Shown
Contents:
Installation Instructions:
Pump Specifications:
Exploded View:
Parts List / Kits:
Torque Specifications:
Repair Instructions:
Pump mounting selection Guide:
Trouble Shooting Guide
Recommened Spare Parts List:
Dimensions:
page 2
pages 3-9
page 10
page 11
page 11
pages 12-13
page 13
page 14
page 15
back page
Updated 3/05
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Specifications
Model P217A-3100/5100
U.S.
(Metric)
1750 RPM+
Ratings ............................................................ 1.8 GPM @ 2000 PSI ...... (6.8 LPM @ 137 bar)
3450 RPM+
Ratings ............................................................ 3.3 GPM @ 2000 PSI ...... (12.5 LPM @ 137 bar)
Plunger Diameter ............................................ 4.76”................................. 18mm
Stroke.............................................................. 1.45”................................. 5.5mm
Temperature of Pumped Fluids ...................... Up to 160o F .................... (71o C)
Inlet Ports (P217A-3100) .......................................................................... (2) 3/8” BSP
Inlet Ports (P217A-5100) .......................................................................... (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............................................................. 11 lbs. 11oz. ..................... (4.9 kg)
Crankcase Oil Capacity .................................. 8.1 fl.oz. ........................... (0.24 liters)
Volumetric Efficiency @ 1750 RPM ......................................................... 0.90
Mechanical Efficiency @ 1750 RPM ........................................................ 0.88
*15 PSI 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.
PULLEY INFORMATION
HORSEPOWER INFORMATION
Pulley selection and pump speed are based on a 1725 Horsepower ratings shown are the power require-
RPM motor and "B" section belts. When selecting ments for the pump. Gas engine power outputs must
desired GPM, allow for a ±5% tolerance on pumps be approximately twice the pump power require-
output due to variations in pulleys, belts and motors ments shown above.
among manufacturers.
1. Select GPM required, then select appropriate when selecting an electric motor as the power source.
motor and pump pulley from the same line. To compute specific pump horsepower requirements,
We recommend that a 1.1 service factor be specified
2. The desired pressure is achieved by selecting the use the following formula:
correct nozzle size that corresponds with the pump
GPM.
GPM X PSI
1450
=hp
P217A-3100/5100 PULLEY SELECTION & HORSEPOWER
REQUIREMENTS
PUMP
PULLEY PULLEY
MOTOR
RPM GPM 800 PSI 1200 PSI 1500 PSI 1700 PSI 2000 PSI
7.75
7.75
7.75
7.75
4.00
6.80
7.25
7.75
1750 1.8
3000 3.0
3200 3.2
3450 3.3
1.0
1.7
1.8
1.8
1.5
2.5
2.6
2.7
1.9
3.1
3.3
3.4
2.1
3.5
3.8
3.9
2.5
4.1
4.4
4.6
3
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Specifications
Model P218A-3100/5100
U.S.
(Metric)
Volume ........................................................... 3.4 GPM ................... (12.5 LPM)
Discharge Pressure ........................................ 2000 PSI ................... (140 bar)
Inlet Pressure ................................................. 90 PSI ....................... (6.2 bar)
RPM................................................................................................... 1750 RPM
Plunger Diameter ........................................... 4.76” ......................... 18mm
Stroke............................................................. 2.64” ......................... 10.0mm
Temperature of Pumped Fluids ..................... 160oF ........................ (71o C)
Inlet Ports (P218A-3100) .................................................................. (2) 3/8” BSP
Inlet Ports (P218A-5100) .................................................................. (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............................................................ 11 lbs. 11oz............... (4.9 kg)
Crankcase Oil Capacity ................................. 8.1 fl.oz..................... (0.24 liters)
Volumetric Efficiency @ 1750 RPM ................................................. 0.96
Mechanical Efficiency @ 1750 RPM ................................................ 0.85
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.
PULLEY INFORMATION
HORSEPOWER INFORMATION
Pulley selection and pump speed are based on a 1725 Horsepower ratings shown are the power require-
RPM motor and "B" section belts. When selecting ments for the pump. Gas engine power outputs must
desired GPM, allow for a ±5% tolerance on pumps be approximately twice the pump power require-
output due to variations in pulleys, belts and motors ments shown above.
among manufacturers.
1. Select GPM required, then select appropriate when selecting an electric motor as the power source.
motor and pump pulley from the same line. To compute specific pump horsepower requirements,
We recommend that a 1.1 service factor be specified
2. The desired pressure is achieved by selecting the use the following formula:
correct nozzle size that corresponds with the pump
GPM.
GPM X PSI
1450
=hp
P218A-3100/5100 PULLEY SELECTION & HORSEPOWER
REQUIREMENTS
PUMP MOTOR
PULLEY PULLEY
RPM GPM 800 PSI 1200 PSI 1500 PSI 1700 PSI 2000 PSI
7.75
7.75
7.75
5.25
6.50
7.25
1725 2.1
1450 2.6
1750 3.4
1.2
1.4
1.9
1.7
2.2
2.8
2.2
2.7
3.5
2.5
3.0
4.0
2.9
3.6
4.7
4
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Specifications
Model P219A-3100/5100
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 ........................................... 4.76” ......................... 18mm
Stroke............................................................. 3.28” ......................... 12.4mm
Temperature of Pumped Fluids ..................... 160oF ........................ (71oC)
Inlet Ports (P219A-3100) .................................................................. (2) 3/8” BSP
Inlet Ports (P219A-5100) .................................................................. (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............................................................ 11 lbs. 11oz............... (4.9 kg)
Crankcase Oil Capacity ................................. 8.1 fl.oz..................... (0.24 liters)
Volumetric Efficiency @ 1750 RPM ................................................. 0.96
Mechanical Efficiency @ 1750 RPM ................................................ 0.85
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.
PULLEY INFORMATION
HORSEPOWER INFORMATION
Pulley selection and pump speed are based on a 1725 Horsepower ratings shown are the power require-
RPM motor and "B" section belts. When selecting ments for the pump. Gas engine power outputs must
desired GPM, allow for a ±5% tolerance on pumps be approximately twice the pump power require-
output due to variations in pulleys, belts and motors ments shown above.
among manufacturers.
1. Select GPM required, then select appropriate when selecting an electric motor as the power source.
motor and pump pulley from the same line. To compute specific pump horsepower requirements,
We recommend that a 1.1 service factor be specified
2. The desired pressure is achieved by selecting the use the following formula:
correct nozzle size that corresponds with the pump
GPM.
GPM X PSI
1450
=hp
P219A-3100/5100 PULLEY SELECTION & HORSEPOWER
REQUIREMENTS
PUMP MOTOR
PULLEY PULLEY
RPM GPM 800 PSI 1200 PSI 1500 PSI 1700 PSI 2000 PSI
7.75
7.75
7.75
5.25
6.50
7.25
1150 2.7
1450 3.5
1750 4.2
1.5
1.9
2.3
2.2
2.9
3.5
2.8
3.6
4.3
3.2
4.1
4.9
3.7
4.8
5.8
5
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Specifications
Model P220A-3100/5100
U.S.
(Metric)
Volume........................................................... 4.7GPM* .................. (17.8 LPM)*
Discharge Pressure ........................................ 2000 PSI ................... (140 bar)
Inlet Pressure ................................................. 90 PSI ....................... (6.2 bar)
RPM................................................................................................... 1750 RPM
Plunger Diameter ........................................... 4.76” ......................... 18mm
Stroke............................................................. 3.73 ........................... 14.1mm
Temperature of Pumped Fluids ..................... 160oF ........................ (71oC)
Inlet Ports (P220A-3100) .................................................................. (2) 3/8” BSP
Inlet Ports (P220A-5100) .................................................................. (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............................................................ 11 lbs. 11oz............... (4.9 kg)
Crankcase Oil Capacity ................................. 8.1 fl.oz..................... (0.24 liters)
Volumetric Efficiency @ 1750 RPM ................................................. 0.96
Mechanical Efficiency @ 1750 RPM ................................................ 0.85
* 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.
PULLEY INFORMATION
HORSEPOWER INFORMATION
Pulley selection and pump speed are based on a 1725 Horsepower ratings shown are the power require-
RPM motor and "B" section belts. When selecting ments for the pump. Gas engine power outputs must
desired GPM, allow for a ±5% tolerance on pumps be approximately twice the pump power require-
output due to variations in pulleys, belts and motors ments shown above.
among manufacturers.
1. Select GPM required, then select appropriate when selecting an electric motor as the power source.
motor and pump pulley from the same line. To compute specific pump horsepower requirements,
We recommend that a 1.1 service factor be specified
2. The desired pressure is achieved by selecting the use the following formula:
correct nozzle size that corresponds with the pump
GPM.
GPM X PSI
1450
=hp
P220A-3100/5100 PULLEY SELECTION & HORSEPOWER
REQUIREMENTS
PUMP MOTOR
PULLEY PULLEY
RPM GPM 800 PSI 1200 PSI 1500 PSI 1700 PSI 2000 PSI
7.75
7.75
7.75
5.25
6.50
7.75
1150 3.1
1450 3.9
1750 4.7
1.7
2.2
2.6
2.6
3.2
3.9
3.2
4.0
4.9
3.6
4.6
5.5
4.3
5.4
6.5
6
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Specifications
Model P221A-3100/5100
U.S.
(Metric)
1750 RPM+
Ratings ................................................... 2.34 GPM @ 2000 PSI ............ (8.9 LPM @ 137 bar)
3450 RPM+
Ratings ................................................... 4.2 GPM @ 2000 PSI .............. (15.9 LPM @ 137 bar)
Inlet Pressure ......................................... -4.35 to 140 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 160o F ............................. (71oC)
Inlet Ports (P221A-3100) .......................................................................... (2) 3/8” BSP
Inlet Ports (P221A-5100) .......................................................................... (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. ............................. (5 kg)
Crankcase Oil Capacity ......................... 7.5 fl.oz. ................................... (0.2 liter)
Extended Crankcase Oil Capacity ......... 9.0 fl.oz. ................................... (0.3 liter)
Volumetric Efficiency @ 1750 RPM ....................................................... 0.95
Volumetric Efficiency @ 3450 RPM ....................................................... 0.87
Mechanical Efficiency @ 1750 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.
HORSEPOWER RATINGS:
P221-3100/5100 HORSEPOWER
REQUIREMENTS
RPM GPM 1000 PSI 1500 PSI 2000 PSI
The rating shown are the power
requirements for the pump. Gas
engine power outputs must be
approximately twice the pump
power requirements shown above.
250 0.3
500 0.7
1000 1.3
1450 1.9
1750 2.3
3000 3.7
3200 3.9
3450 4.2
0.2
0.5
0.9
1.3
1.6
2.5
2.7
2.9
0.3
0.7
1.4
2.0
2.4
3.8
4.0
4.3
0.5
0.9
1.8
2.7
3.2
5.0
5.4
5.8
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:
*Intermittent duty only
HP = (GPM X PSI) / 1450
7
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Specifications
Model P227-3100/5100
U.S.
(Metric)
1750 RPM+
Ratings ............................................................ 2.1 GPM @ 2000 PSI ...... (8.0 LPM @ 137 bar)
3450 RPM+
Ratings ............................................................ 3.8 GPM @ 2000 PSI ...... (14.4 LPM @ 137 bar)
Inlet Pressure .................................................. -4.35 to 140 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 160o F ..................... (71oC)
Inlet Ports (P227A-3100) .......................................................................... (2) 3/8” BSP
Inlet Ports (P227A-5100) .......................................................................... (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. ..................... (5 kg)
Crankcase Oil Capacity .................................. 7.5 fl.oz. ........................... (0.2 liter)
Extended Crankcase Oil Capacity .................. 9.0 fl.oz. ........................... (0.3 liter)
Volumetric Efficiency @ 1750 RPM ........................................................ 0.95
Volumetric Efficiency @ 3450 RPM ........................................................ 0.87
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.
HORSEPOWER RATINGS:
P227-3100/5100 HORSEPOWER
The rating shown are the power
requirements for the pump. Gas
engine power outputs must be
REQUIREMENTS
RPM GPM 1000 PSI 1500 PSI 2000 PSI
250 0.3
500 0.6
1000 1.2
1450 1.7
1750 2.1
3000 3.3
3200 3.5
3450 3.8
0.2
0.4
0.8
1.2
1.4
2.3
2.4
2.6
0.3
0.6
1.2
1.8
2.2
3.4
3.6
3.9
0.4
0.8
1.7
2.4
2.9
4.6
4.9
5.2
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
8
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Specifications
Model P230-3100/5100
U.S.
(Metric)
1750 RPM+
Ratings ............................................................ 1.1 GPM @ 2000 PSI ...... (4.2 LPM @ 137 bar)
3450 RPM+
Ratings ............................................................ 2.05 GPM @ 2000 PSI .... (7.8 LPM @ 137 bar)
Inlet Pressure .................................................. 14 to 140 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 160oF ...................... (71oC)
Inlet Ports (P230-3100) ............................................................................. (2) 3/8” BSP
Inlet Ports (P230-5100) ............................................................................. (2) 1/2” BSP
Discharge Ports.......................................................................................... (2) 3/8" BSP
Shaft Rotation .............................................................................................. Top ofPulley Towards Fluid End
Crankshaft Diameter ................................................................................. 24mm
Key Width.................................................................................................. 8mm
Shaft Mounting .......................................................................................... Right Side Facing Manifold
Weight............................................................. 11 lbs. 11oz. ..................... (5 kg)
Crankcase Oil Capacity .................................. 7.5 fl.oz. ........................... (0.2 liter)
Extended Crankcase Oil Capacity .................. 9.0 fl.oz. ........................... (0.3 liter)
Volumetric Efficiency @ 1750 RPM ........................................................ 0.94
Volumetric Efficiency @ 3450 RPM ........................................................ 0.87
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.
HORSEPOWER RATINGS:
P230-3100/5100 HORSEPOWER
The rating shown are the power
requirements for the pump. Gas
engine power outputs must be
REQUIREMENTS
RPM GPM 1000 PSI 1500 PSI 2000 PSI
250 0.2
500 0.3
1000 0.6
1450 0.9
1750 1.1
3000 1.8
3200 1.9
3450 2.0
0.1
0.2
0.4
0.6
0.8
1.2
1.3
1.4
0.2
0.3
0.7
0.9
1.1
1.8
2.0
2.1
0.2
0.4
0.9
1.3
1.5
2.5
2.6
2.8
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
9
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Exploded View - P200A-3100/5100 Series
10
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P200A-3100/5100 SERIES PARTS LIST
ITEM PART NO. DESCRIPTION
QTY.
1
ITEM PART NO. DESCRIPTION
QTY.
1
08300
08301
08302
Crankcase
17
19
20
21
21
23
23A
23B
24
25
26
26
27
28
29
30
31
31
32
33
33
34
36
36
36A
08442
Wrist Pin
3
3
3
3
3
3
3
3
3
3
2
Dipstick
1
08356-0010 Oil Seal
3
Crankcase Plug Cover
1
08444-0100 Seal Retainer, 316 S.S.
12260-0001 O-Ring (“-3100” pumps)
3A
4
07190-0100 Drain Plug & Gasket
1
08005
O-Ring
1
08443
08477
08087
06163
07904
O-Ring (“-5100” pumps)
Grooved Seal
5
6
08185-0100 Oil Drain Plug with seal
07188-0100 Screw, 316 S.S.
1
4
Grooved Seal Ring, Brown
Drip Shield
6A
7
07223-0100 Spring Washer, 316 S.S.
4
08303
08490
08492
Bearing Cover I
Sight Glass
O-Ring
2
Pressure Ring
08445-0100 Weep Return Ring, 316 S.S.
8
9
1
1
06582-3000 Valve Casing (“-3100” pumps) 1
06582-5000 Valve Casing (“-5100” pumps) 1
07849-0100 Valve Seat
07491-0100 Valve Plate
07906-0100 Valve Spring
10
10A
11
12A
12B
13
13
13
13
13
13
13
14
15
16
16A
16B
16C
16D
07225-0100 Screw
07223-0100 Spring Washer
8
8
6
6
6
6
6
6
6
6
6
8
1
1
01166
08020
01020
08465
08440
08466
08467
12258
06547
06694
06207
08333
Radial Shaft Seal
1
Ball Bearing
1
Ball Bearing
1
07907
Valve Spring Retainer
Crankshaft(P217A-3100/5100)
Crankshaft(P218A-3100/5100)
Crankshaft(P219A-3100/5100)
Crankshaft(P220A-3100/5100)
Crankshaft(P221A-3100/5100)
Crankshaft(P227A-3100/5100)
Crankshaft(P230A-3100/5100)
Woodruff Key
1
7853-0001 O-Ring (“-3100” pumps)
1
07853
07928-0100 Plug
O-Ring (“-5100” pumps)
1
1
07913-0001 O-Ring (“-3100” pumps)
1
07913
O-Ring (“-5100” pumps)
1
08316-0100 Hex Head Cap Screw
1
13338-0300 Plug, 3/8”, (“-3100” pumps)
13338-0100 Plug, 3/8”, (“-5100” pumps)
1
Connecting Rod
3
08486
Copper Washer, 3/8”,
(“-3100” pumps only)
08469-0100 Plunger, Complete 18mm
08468-0100 Plunger Base, 316 S.S.
3
1
1
1
3
37
07109-0300 Plug, 1/2”, (“-3100” pumps)
07109-0100 Plug, 1/2”, (“-5100” pumps)
08455
Plunger
3
37
08456-0100 Tension Screw, 316 S.S.
07204-0100 Crush Washer, 316 S.S.
3
37A
06272
Copper Washer, 1/2”,
3
(“-3100” pumps only)
1
P200A-3100/5100 SERIES REPAIR KITS
Plunger Packing Kit
Part# 09602
Item Part # Description
23 08477 Grooved Seal
23A 08087 Grooved Seal Ring
23B 06163 Drip Shield
24 07904 Pressure Ring
Valve Assembly Kit
Oil Seal Kit
Part# 09144
Item Part #
19 08356-0010 Oil Seal
Part # 09211
Item Part #
Qty.
3
3
3
3
Description
Qty.
6
6
6
6
Description Qty.
27 07849-0100 Valve Seat
28 07491-0100 Valve Plate
3
29 07906
30 07907
Valve Spring
Valve Retainer
31 07853-0001 O-Ring
6
P200A-3100/5100 SERIES TORQUE SPECIFICATIONS
Position
Item#
Description
Tension Screw, Plunger
Valve Plug
Torque Amount (ft.-lbs)
220 (in.-lbs.)
16C
32
34
08456-0100
07928-0100
08316-0100
33 (ft.-lbs.)
105 (in.-lbs.)
Hex Head Cap Screw, Valve Casing
11
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REPAIR INSTRUCTION - P200A-3100/5100 SERIES
1. With a 22mm socket
3. By inserting a small screw
2. Using a needle nose pliers,
remove the inlet and
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.
driver between the valve
seat (27) and the valve
spring retainer (30), the
valve assembly can be
separated.
discharge valve assemblies
(27-30) and o-ring (31).
Inspect all parts for wear
and replace as necessary.
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.
16
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) from the seal case
(20). Inspect all parts,
including o-ring (21) for
wear and replace as
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.
necessary
12
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REPAIR INSTRUCTION - P200A-3100/5100 SERIES
Disassembly sequence of the back end of the P200A-3100/5100 series pump.
1)
2)
Before you begin, drain the oil from the crankcase.
Remove the crankcase cover (3) and o-ring (4) from the crankcase (1). To remove the crankshaft (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)
4)
5)
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.
Remove the connecting rod (15) and plunger (16). Remove the wrist pin (17) if necessary. Check the
plunger bore in the crankcase for wear. Inspect parts and replace as necessary.
Should you find it necessary to service the plunger assembly (#16) you can do so by removing the tension
screw (#16D). Inspect all parts and replace as necessary.
Reassembly sequence of the of the P200A-3100/5100 series pump
1)
Reassemble plunger (16) and the connecting rod (15) with wrist pin (17). Place assemblies in crankcase
(1). Install crankshaft through connecting rods again being careful not to bend or otherwise damage the
connecting 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 crankcase. Replace radial shaft
seal (11), bearing cover (7), sight glass (8), and crankcase cover (3) with its o-ring (4).
3)
4)
If oil seals (19) were removed, replace with seal lip towards crankcase. Lubricate seal before replacing.
Replace seal case (20) with o-rings (21) over plungers. Generously lubricate o-rings and oil seal before
reassembly. Replace v-sleeve (23) over plungers (16)..
5)
Generously lubricate v-sleeve (23). Assemble v-sleeves (22) 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 (see below).
6)
Replace the six o-rings (31)
and the six valve assemblies
(27-30). Now replace the six
7
6
5
8
3
1
2
4
valve plugs with o-rings (32
and 33) and tighten securely
with a 22mm socket wrench to
33 foot-pounds.
7)
Fill crankcase with 8.1 ounces
of oil.
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”)
13
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PUMP SYSTEM MALFUNCTION
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
Replace nozzle
Clean valve assembly
Clean strainer
Repair/Replace hose
Clean, Reset, and Replace worn parts
Check suction lines on inlet of
Worn or Damaged nozzle
Fouled discharge valve
Fouled inlet strainer
Worn or Damaged hose
Worn or Plugged relief valve on pump
Cavitation
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
oil with
Cavitation
Replace bearings, Refill crankcase
recommended lubricant
Check inlet lines for restrictions
and/or proper sizing
Rough/Pulsating
Operation with
Pressure Drop
Worn packing
Inlet restriction
Replace packing
Check system for stoppage, air
leaks, correctly sized inlet
plumbing to pump
Accumulator pressure
Unloader
Cavitation
Recharge/Replace accumulator
Check for proper operation
Check inlet lines for restrictions
and/or proper size
Pressure Drop at Gun
Restricted discharge plumbing
Re-size discharge plumbing to
flow rate of pump
Excessive
Leakage
Worn plungers
Replace plungers
Worn packing/seals
Excessive vacuum
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
X
X
Seal Spare Parts (1 kit/pump)
(See page 11 for kit list)
Oil Seal Kit (1 kit/pump)
(See page 11 for kit lit)
Valve Spare Parts (1 kit/pump)
(See page 11 for kit list)
X
X
X
14
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P200A-3100/5100 DIMENSIONS - INCHES (mm)
15
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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 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.
Thiswarrantyislimitedtorepairorreplacementofpumpsandaccessoriesofwhichthe 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, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION ANY WAR-
RANTIESORMERCHANTABILITYORFITNESSFORAPARTICULARPURPOSEANDALLSUCH
WARRANTIES ARE HEREBY DISCLAIMED AND EXCLUDED BY THE MANUFACTURER.
GIANT INDUSTRIES, INC., 900 N. Westwood Ave., P.O. Box 3187, Toledo, Ohio 43607
Copyright 2005 Giant Industries, Inc.
3/05 P200A-3100_5100.PMD
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