Giant Heat Pump P200A 3100 User Manual

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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