Triplex Ceramic
Plunger Pump
OperatingInstructions/
Repair and Service
Manual
Pump
P220-3000
Contents:
InstallationInstructions:
PumpSpecifications:
Exploded View:
Kits:
page 2
pages 3
page 4
page 4
page 5
page 5
PartsList:
TorqueSpecifications:
PumpMountingSelection
Guide:
page 5
Recommended
RepairInstructions:
Spare Parts List:
Dimensions:
pages 6-7
page 7
back page
back page
WarrantyInformation:
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Specifications
Model P220-3000
Volume ............................................................................................................ Up to 4.7GPM
Discharge Pressure......................................................................................... Up to 2000 PSI
Inlet Pressure .................................................................................................. 14 to 140 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
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.
Volumetric Efficiency @ 1750 RPM .............................................................. 0.95
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 crank-
case 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:
P220-3000 HORSEPOWER
The rating shown are the power
requirements for the pump. Gas
engine power outputs must be
approximately twice the pump
REQUIREMENTS
RPM GPM 1000 PSI 1500 PSI 1700 PSI 2000 PSI
250 0.7
500 1.3
1000 2.7
1450 3.8
1750 4.7
0.5
0.9
1.9
2.6
3.2
0.7
1.3
2.8
3.9
4.9
0.8
1.5
3.2
4.5
5.5
1.0
1.8
3.7
5.2
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
3
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Exploded View
P220-3000 Pump
Repair Kits
P220-3000 Pumps
Plunger Packing Kit
Oil Seal Kit
Part # 09164
Part # 09144
Item # Qty.
Part # Description
Item # Qty.
Part #
Description
Oil Seal
23
23A
24
3
3
3
08477 V-Sleeve, weep
08087 V-Sleeve, brown
07904 Pressure Ring
19
3
08356-0010
Valve Assembly Kit
Part # 09116
Item # Qty.
Part # Description
32X
31
6
6
07946 ValveAssembly Complete
07853 O-Ring
4
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Spare Parts
P220-3000 Pump
ITEM PARTNO. DESCRIPTION
QTY.
1
ITEM PARTNO. DESCRIPTION
QTY.
1
08300
06773
08302
08302-L
07190
08005
06273
08192
07188
01176-2
08303
08490
08492
07225
01166
08020
01020
08467
06207
08333
Crankcase
16B
16C
16D
17
08455
PlungerPipe
3
3
3
3
3
3
3
3
3
3
3
3
2
OilDipstickwithO-Ring
Crankcase Cover, Short
Crancase Cover, Long
Drain Plug & Gasket
O-Ring
1
08456-0100 Tension Screw
3
1
07204-0100 Crush Washer, 316 S.S.
3
1
08442
07770
Wrist Pin
O-Ring
3A
4
1
18
1
19
08356-0010 OilSeal
5
OilDrainPlug
1
20
08444
08443
08477
08087
07904
08445
Seal Case
O-Ring
V-Sleeve,Weep
V-Sleeve,Brown
Pressure Ring
Weep Return Ring
5A
6
Gasket
1
21
Screw,CrankcaseCover
Spring Washer
Bearing Cover I
Sight Glass
4
23
6A
7
4
23A
24
2
8
9
1
25
O-Ring
1
26
08446-5000 Valve Casing 3/8" Inlet Ports 1
10
11
12A
12B
13
14
15
16
16A
16B
16C
16D
17
18
Screw with Lock Washer
RadialShaftSeal
BallBearing
8
27
07849
07491
07906
07907
07853
07928
07946
07913
08316
13338
08486
07109
07661
ValveSeat
6
6
6
6
6
6
6
6
8
1
1
1
1
1
28
ValvePlate
1
29
ValveSpring
BallBearing
Crankshaft
Woodruff Key
Connecting Rod
1
30
ValveSpringRetainer
O-Ring
1
31
32
1
ValvePlug
ValveAssemblyComplete
O-Ring
HexHeadCapScrew
Plug, 3/8"BSP
Copper Crush Washer, 3/8”
Plug, 1/2"BSP
Seal
3
32X
33
08469-0100 Plunger,Complete,18mm
3
08468
08455
Plunger Base
PlungerPipe
3
34
38
3
08456-0100 Tension Screw
3
38A
39
07204-0100 Crush Washer, 316 S.S.
08442
07770
3
Wrist Pin
O-Ring
3
39A
3
Pump Torque Specifications
P220-3000
Position
Item#
Description
Torque Amount
16C
32
08456-0100
Tension Screw, Plunger
Valve Plug
220 (in.-lbs.)
59 (ft.-lbs.)
105 (in.-lbs.)
07928
08316
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”)
5
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REPAIR INSTRUCTIONS - P220-3000 PUMP
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
(32X).
damaged.
4. Remove the o-ring (31).
Inspect all parts for wear
and replace as necessary.
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.
(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).
Remove the v-sleeve
(23A) from the seal case
6
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REPAIR INSTRUCTIONS - P220-3000 PUMP
NOTE: If there are
deposits of any kind (i.e.,
lime deposits) in the
10. If the ceramic plunger pipe
(16B) is damaged, remove
the plunger bolt (16C).
valve casing, be certain
that the weep holes in the
weep return ring (25)
and valve casing (26)
have not been plugged.
Discard the old plunger
pipe (16B) and copper
gasket (16D), and clean the
old locktite from the
plunger bolt (16C) and
plunger base (16A). (For
pumps that use the 316
S.S. crush washer (16D),
fatten the washer prior
to plunger reassembly)
Replace the plunger with
the new one and locktite
the plunger bolt and torque
to 220 inch-pounds.
Reassembly sequence of the P220-3000 pump
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). 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.
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
X
X
Seal Spare Parts (1 kit/pump)
(See page 4 for kit list)
Oil Seal Kit (1 kit/pump)
X
X
(See page 4 for kit lit)
Valve Spare Parts (1 kit/pump)
X
(See page 4 for kit list)
NOTE: Contact Giant Industries for Service School Information. Phone: (419)-531-4600
7
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P220-3000 DIMENSIONS (inches)
GIANTINDUSTRIESLIMITEDWARRANTY
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.
4/02P220-3000.PM6
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