Triplex Ceramic
PlungerPump
OperatingInstructions/
Repair and Service
Manual
Series
P200A-3100/5100
Stainless Steel Shown
Contents:
InstallationInstructions: page2
PumpSpecifications:
Parts List / Kits:
pages3-7
page8
TorqueSpecifications:
ExplodedView:
page8
page9
RepairInstructions:
WarrantyInformation:
page10-11
backpage
Updated 3/98
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Specifications
Model P217A-3100/5100
Volume........................................................................................................ Up to 3.4 GPM
Discharge Pressure ..................................................................................... Up to 2000 PSI
Inlet Pressure .............................................................................................. Up to 90 PSI
RPM ........................................................................................................... Up to 3450 RPM
Plunger Diameter ....................................................................................... 18mm
Stroke ......................................................................................................... 5.5mm
Temperature of Pumped Fluids .................................................................. Up to 160o F
Inlet Ports ................................................................................................... (2) 3/8" 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 ............................................................................. 6.5 fl.oz.
Volumetric Efficiency @ 1750 RPM ........................................................ 0.90
Mechanical Efficiency @ 1750 RPM ....................................................... 0.88
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
P217A-3100/5100 HORSEPOWER
REQUIREMENTS
requirements for the pump. Gas
RPM GPM 800 PSI 1200 PSI 1500 PSI 1700 PSI 2000 PSI
engine power outputs must be
1725 1.7
3000 3.0
3200 3.2
3450 3.4
0.9
1.7
1.8
1.9
1.4
2.5
2.6
2.8
1.7
3.1
3.3
3.5
2.0
3.5
3.8
4.0
2.3
4.1
4.4
4.7
approximately twice the pump
power requirements shown above.
We recommend a 1.15 service
factor
selecting anelectric motor as the
power source. To compute
specific pump horsepower require-
be specified when
ments, use the
ing formula:
follow-
HP = (GPM X PSI) / 1450
SPECIAL NOTE:
The theoretical gallons per revolution
(gal/rev) is 0.0009855.
To find specific outputs at various RPM,
use the formula: GPM = 0.0009855 x RPM
3
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Specifications
Model P218A-3100/5100
Volume........................................................................................................ Up to 3.4 GPM
Discharge Pressure ..................................................................................... Up to 2000 PSI
Inlet Pressure .............................................................................................. Up to 90 PSI
RPM ........................................................................................................... Up to 1750 RPM
Plunger Diameter ....................................................................................... 18mm
Stroke ......................................................................................................... 10.0mm
Temperature of Pumped Fluids .................................................................. Up 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
Key Width .................................................................................................. 8mm
Shaft Mounting........................................................................................... Right Side Facing Manifold
Weight ........................................................................................................ 11 lbs. 11oz.
Crankcase Oil Capacity ............................................................................. 9.5 fl.oz.
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.
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.
P218A-3100/5100 HORSEPOWER
REQUIREMENTS
RPM GPM 800 PSI 1200 PSI 1500 PSI 1700 PSI 2000 PSI
1150 2.1
1450 2.6
1750 3.4
1.2
1.5
1.9
1.7
2.2
2.8
2.2
2.7
3.5
2.5
3.1
4.0
2.9
3.6
4.7
We recommend a 1.15 service
factor
selecting anelectric motor as the
power source. To compute
specific pump horsepower require-
be specified when
ments, use the
ing formula:
follow-
HP = (GPM X PSI) / 1450
SPECIAL NOTE:
The theoretical gallons per revolution
(gal/rev) is 0.00193.
To find specific outputs at various RPM,
use the formula: GPM = 0.00193 x
RPM
4
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Specifications
Model P219A-3100/5100
Volume ............................................................................................................ Up to 4.2 GPM
Discharge Pressure.......................................................................................... Up to 2000 PSI
Inlet Pressure................................................................................................... Up to 90 PSI
RPM................................................................................................................ Up to 1750 RPM
Plunger Diameter............................................................................................ 18mm
Stroke .............................................................................................................. 12.4mm
Temperature of Pumped Fluids ...................................................................... Up 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
Key Width....................................................................................................... 8mm
Shaft Mounting ............................................................................................... Right Side of Manifold
Weight............................................................................................................. 11 lbs. 11oz.
Crankcase Oil Capacity.................................................................................. 9.5 fl.oz.
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.
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.
P219A-3100/5100 HORSEPOWER
REQUIREMENTS
RPM
1150
1450
1750
GPM
2.7
3.5
1000 PSI 1500 PSI 2000 PSI
We recommend a 1.15 service
1.9
2.4
2.9
2.8
3.6
4.3
3.7
4.8
5.8
factor
selecting anelectric motor as the
power source. To compute
specific pump horsepower require-
be specified when
4.2
ments, use the
ing formula:
follow-
HP = (GPM X PSI) / 1450
SPECIAL NOTE:
The theoretical gallons per revolution
(gal/rev) is 0.00239.
To find specific outputs at various RPM,
use the formula: GPM = 0.00239 x
RPM
5
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Specifications
Model P220A-3100/5100
Volume ............................................................................................................ Up to 4.7GPM
Discharge Pressure.......................................................................................... Up to 2000 PSI
Inlet Pressure................................................................................................... Up to 90 PSI
RPM................................................................................................................ Up to 1725 RPM
Plunger Diameter............................................................................................ 18mm
Stroke .............................................................................................................. 14.1mm
Temperature of Pumped Fluids ...................................................................... Up 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
Key Width....................................................................................................... 8mm
Shaft Mounting ............................................................................................... Right Side Facing Manifold
Weight............................................................................................................. 11 lbs. 11oz.
Crankcase Oil Capacity.................................................................................. 9.5 fl.oz.
Volumetric Efficiency @ 1750 RPM............................................................. 0.945
Mechanical Efficiency @ 1750 RPM ........................................................... 0.86
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:
P220A-3100/5100 HORSEPOWER
The rating shown are the power
requirements for the pump. Gas
engine power outputs must be
approximately twice the pump
REQUIREMENTS
RPM GPM 800 PSI 1200 PSI 1500 PSI 1700 PSI 2000 PSI
1150 3.1
1450 3.9
1750 4.7
1.7
2.1
2.6
2.5
3.2
3.9
3.2
4.0
4.9
3.6
4.6
5.5
4.2
5.4
6.5
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
SPECIAL NOTE:
The theoretical gallons per revolution
(gal/rev) is 0.00266.
To find specific outputs at various RPM,
use the formula: GPM = 0.00266 x
RPM
6
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Specifications
Model P221A-3100
Volume ............................................................................................................ Up to 2.3GPM
Discharge Pressure.......................................................................................... Up to 2000 PSI
Inlet Pressure................................................................................................... Up to 90 PSI
RPM................................................................................................................ Up to 1750 RPM
Plunger Diameter............................................................................................ 18mm
Stroke .............................................................................................................. 14.1mm
Temperature of Pumped Fluids ...................................................................... Up 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
Key Width....................................................................................................... 8mm
Shaft Mounting ............................................................................................... Right Side Facing Manifold
Weight............................................................................................................. 11 lbs. 11oz.
Crankcase Oil Capacity.................................................................................. 9.5 fl.oz.
Volumetric Efficiency @ 1750 RPM............................................................. 0.90
Mechanical Efficiency @ 1750 RPM ........................................................... 0.88
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
power requirements shown above.
P221A-3100 HORSEPOWER REQUIREMENTS
RPM GPM 800 PSI 1200 PSI 1500 PSI 1700 PSI 2000 PSI
1150 1.5
1450 1.9
1750 2.3
0.8
1.0
1.3
1.2
1.6
1.9
1.6
2.0
2.4
1.8
2.2
2.7
2.1
2.6
3.2
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
SPECIAL NOTE:
The theoretical gallons per revolution
(gal/rev) is 0.00131.
To find specific outputs at various RPM,
use the formula: GPM = 0.00131 x RPM
7
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P200A-3100/5100 SERIES PARTS LIST
ITEM PART NO. DESCRIPTION
QTY.
ITEM PART NO. DESCRIPTION
QTY.
1
2
08300
08301
Crankcase
1
17
18
19
20
20
21
21
23
23
23A
08442
07770
Wrist Pin
3
3
3
3
3
3
3
6
3
Oil Fill Plug with Gasket
(P217-5100 & P221A-3100
Dipstick
O-Ring (P221-3100)
1
08356-0010 Oil Seal
2
08480
08302
07190
08005
08185
08444-0100 Seal Case
3
Crankcase Plug Cover
Drain Plug & Gasket
O-Ring
1
1
1
1
4
12259-0300 Seal Retainer (P221-3100)
3A
4
08443
O-Ring
12260-0300 O-Ring (P221-3100)
5
6
Oil Drain Plug
08087
8477
8087
V-Sleeve
07188-0100 Screw, 316 S.S.
Grooved Seal (P221-3100)
Grooved Seal Ring, Brown
(P221-3100)
6A
7
07223-0100 Spring Washer, 316 S.S.
08303
08490
08492
Bearing Cover I
Sight Glass
O-Ring
2
1
1
8
8
1
1
1
1
1
1
1
1
1
3
3
3
3
3
3
3
3
3
3
1
1
6
6
6
6
6
6
6
6
6
6
8
2
2
8
9
24
24
25
26
26
27
28
29
30
31
31
32
32
33
33
34
36
36
07904
Pressure Ring
12261-0300 Support Ring (P221-3100)
08445-0100 Weep Return Ring, 316 S.S.
08446-5000 Valve Casing
10
10A
11
12A
12B
13
13
13
13
13
14
15
16
16A
16B
16C
16D
07225-0100 Screw with Lock Washer
07223-0100 Spring Washer
01166
08020
01020
08465
08440
08466
08467
12258
06207
08333
Radial Shaft Seal
12262-3000 Valve Casing (P221-3100)
07849-0100 Valve Seat
Ball Bearing
Ball Bearing
07491-0100 Valve Plate
Crankshaft (P217A Series)
Crankshaft (P218A Series)
Crankshaft (P219A Series)
Crankshaft (P220A Series)
Crankshaft (P221A-3100)
Woodruff Key
07906
07907
07853
Valve Spring
Valve Spring Retainer
O-Ring
7853-0001 O-Ring
07928-0100 Valve Plug
12263-0300 Plug (P221-3100)
Connecting Rod
07913
O-Ring
08469-0100 Plunger, Complete 18mm
08468-0100 Plunger Base
12264-0300 O-Ring (P221-3100)
08613-0100 Hex Head Cap Screw
08455
Plunger Pipe
12138
12265
Plug
Plug (P221-3100)
08456-0100 Tension Screw
07204-0100 Copper Gasket, 316 S.S.
P200A-3100/5100 SERIES REPAIR KITS
Valve Assembly Kit
Plunger Packing Kit
Part# 09164
Plunger Packing Kit
Part # 09460 (P221A-3100)
Part # 09211
Qty.
6
6
Part #
Description
Valve Seat
Valve Plate
Valve Spring
Valve Retainer
O-Ring
Qty.
Part # Description
Qty.
3
3
3
Part #
08087
08477
07904
Description
V-Sleeve
Groved Seal
Pressure Ring
07849-0100
07491-0100
07906
6
08087 V-Sleeve
3
07904 Pressure Ring
6
6
07907
Oil Seal Kit
Part# 09144
6
07853
Qty.
3
Part #
08356-0010
Description
Oil Seal
P200A-3100/5100 SERIES TORQUE SPECIFICATIONS
Position
Item#
08456
07928
08316
Description
Tension Screw, Plunger
Valve Plug
Hex Head Cap Screw, Valve Casing
Torque Amount (ft.-lbs)
120 (in.-lbs.)
16C
32
34
33 (ft.-lbs.)
105 (in.-lbs.)
8
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Exploded View - P200A-3100/5100 Series
9
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REPAIR INSTRUCTION - P200A-3100/5100 SERIES
Disassembly sequence of fluid end of P200A-3100/5100 series pump
Note: Always take time to lubricate all metal and nonmetal parts with a light film of oil before reassem-
bly. This step will ensure proper fit, at the same time protecting the pump nonmetal parts (i.e., the
elastomers) from cutting and scoring.
1)
2)
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 damaged.
Using a needle nose pliers, remove the inlet and discharge valve assemblies (32X). By inserting a
small screw driver between the valve seat (27) and the valve spring retainer (30), the valve assembly
can be separated. Remove the o-ring (31). Inspect all parts for wear and replace as necessary.
3)
Next, use a 5mm allen wrench to remove the 8 socket head cap screws (34). Carefully slide the valve
casing (26) out over the plungers. Remove the weep return ring (25), pressure ring (24), and v-sleeve
(23) from the valve casing (26). Remove the v-sleeve (23) from the seal case (20). Inspect all parts,
including o-ring (21) for wear and replace as necessary.
4)
5)
Check surfaces of plunger (16). A damaged surface will cause accelerated wear on the seals. Deposits
of any kind must be carefully removed from the plunger surface. A damaged plunger must be re-
placed!
If the ceramic plunger pipe (16B) is damaged, remove the plunger bolt (16C). Discard the old plunger
pipe (16B) and copper gasket (16D), and clean the old locktite from the plunger bolt (16C) and
plunger base (16A). Replace the plunger with the new one and locktite the plunger bolt and torque to
120 inch-pounds.
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.
5)
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. If the oil seals are not to be replaced,
proceed to the back end disassembly sequence and carefully pry the seals loose after the plungers have
been removed from the crankcase. The seals should not be reinstalled until after step #2 of the "Reas-
sembly Sequence".
10
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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.
6)
7)
Replace the six o-rings (31) and the six valve assemblies (32X). Now replace the six valve plugs with o-
rings (32 and 33) and tighten securely with a 22mm socket wrench to 33 foot-pounds.
Fill crankcase with 9.5 ounces (6.5 ounces for P217A) of oil.
NOTE: Contact Giant Industries for Service School Information. Phone: (419)-531-4600
11
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P200A-3100/5100 DIMENSIONS (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
pump
warranted
SALINE,
never fail, period. If they ever fail, we will replace them free of charge. Our other
parts, used in portable pressure washers and in car wash applications, are
for five years from the date of shipment for all pumps used in NON-
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
PHONE(419)531-4600,FAX(419)531-6836,www.giantpumps.com
Copyright1998GiantIndustries,Inc.
3/98P200A-3100.PM6
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