Triplex Ceramic
Plunger Pump
Operating Instructions/
Repair and Service
Manual
Series
P200-12mm versions
P205
P206
P207
TM
P208
P209
P210
P211
Contents:
Installation Instructions:
Pump Specifications:
Exploded View:
page 2
pages 3-9
page 10
page 11
Parts List:
Kits & Torque Specifications:page 12
Pump Mounting Selection
Guide:
page 12
Repair Instructions:
Recommended
Spare Parts List:
Dimensions:
pages 13-14
page 14
page 15
back page
Warranty Information:
Updated 7/07
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Specifications
Model P205
1750 RPM+
...................................................................................................
U. .S.
Metric
Flow (Continuous) @ 2000 PSI (140 Bar) .......... 0.5 GPM ....................... 1.9 L/min
Flow (Intermittent) @ 2500 PSI (175 Bar) ......... 0.5 GPM ....................... 1.9 L/min
3450 RPM+
Flow (Continuous) @ 2000 PSI (140 Bar) .......... 0.9 GPM ....................... 2.4 L/min
Flow (Intermittent) @ 2000 PSI (140 Bar) ......... 0.9 GPM ....................... 2.4 L/min
Maximum Inlet Pressure ..................................... 145 PSI......................... 10 Bar
Plunger Diameter ................................................. 0.47” ............................. 12 mm
Stroke................................................................... 0.13” ............................. 3.4 mm
Max. Temperature of Pumped Fluids .................. 160o F............................ 70o C
Inlet Ports.................................................................................................... (2) 1/2" BSP
Discharge Ports........................................................................................... (2) 3/8" BSP
Shaft Rotation ...................................................... Top of Pulley Towards Fluid End
Crankshaft Diameter............................................ 0.98” ............................. 24 mm
Key Width ........................................................... 0.31” ............................. 8 mm
Shaft Mounting .................................................... Right Side Facing Manifold
Weight ................................................................. 11.7 lbs. ........................ 5.3 Kg
Crankcase Oil Capacity ....................................... 7.5 fl.oz. ....................... 0.22 Liters
Extended Crankcase Oil Capacity ....................... 9.0 fl.oz. ....................... 0.27 Liters
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:
The rating shown are the power
requirements for the pump. Gas
engine power outputs must be
approximately twice the pump
power requirements shown above.
P205 HORSEPOWER REQUIREMENTS
RPM GPM 1000 PSI 1500 PSI 2000 PSI 2500 PSI*
500 0.13
1000 0.29
1750 0.50
3000 0.78
3200 0.84
3450 0.90
0.1
0.2
0.3
0.5
0.6
0.6
0.1
0.3
0.5
0.8
0.9
0.9
0.2
0.4
0.7
1.1
1.2
1.2
0.2
0.5
0.9
1.4
1.4
1.6
We recommend a 1.15 service factor
be specified when selecting an
electricmotor as the power source.
To compute specific pump horse
power requirements, use the
following formula:
*intermittent duty
HP = (GPM X PSI) / 1450
3
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Specifications
Model P206
1750 RPM+
...................................................................................................
U. .S.
Metric
Flow (Continuous) @ 2000 PSI (140 Bar) .......... 0.8 GPM ....................... 3.0 L/min
Flow (Intermittent) @ 2500 PSI (175 Bar) ......... 0.8 GPM ....................... 3.0 L/min
3450 RPM+
Flow (Continuous) @ 2000 PSI (140 Bar) .......... 1.5 GPM ....................... 5.7 L/min
Flow (Intermittent) @ 2000 PSI (140 Bar) ......... 1.5 GPM ....................... 5.7 L/min
Maximum Inlet Pressurez.................................... 145 PSI......................... 10 Bar
Plunger Diameter ................................................. 0.47” ............................. 12 mm
Stroke................................................................... 0.22” ............................. 5.5 mm
Max. Temperature of Pumped Fluids .................. 160o F............................ 70o C
Inlet Ports.................................................................................................... (2) 1/2" BSP
Discharge Ports........................................................................................... (2) 3/8" BSP
Shaft Rotation ...................................................... Top of Pulley Towards Fluid End
Crankshaft Diameter............................................ 0.98” ............................. 24 mm
Key Width ........................................................... 0.31” ............................. 8 mm
Shaft Mounting .................................................... Right Side Facing Manifold
Weight ................................................................. 11.7 lbs. ........................ 5.3 Kg
Crankcase Oil Capacity ....................................... 7.5 fl.oz. ....................... 0.22 Liters
Extended Crankcase Oil Capacity ....................... 9.0 fl.oz. ....................... 0.27 Liters
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:
The rating shown are the power
requirements for the pump. Gas
engine power outputs must be
approximately twice the pump
power requirements shown above.
P206 HORSEPOWER REQUIREMENTS
RPM GPM 1000 PSI 1500 PSI 2000 PSI 2500 PSI*
250 0.11
500 0.21
1000 0.43
1750 0.76
3000 1.30
3200 1.40
3450 1.50
0.1
0.1
0.3
0.5
0.9
1.0
1.0
0.1
0.2
0.4
0.8
1.3
1.4
1.6
0.2
0.3
0.6
1.0
1.8
1.9
2.1
0.2
0.4
0.7
1.3
2.2
2.4
2.6
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
4
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Specifications
Model P207
1750 RPM+
...................................................................................................
U. .S.
Metric
Flow (Continuous) @ 2000 PSI (140 Bar) .......... 0.9 GPM ....................... 3.4 L/min
Flow (Intermittent) @ 2500 PSI (175 Bar) ......... 0.9 GPM ....................... 3.4 L/min
3450 RPM+
Flow (Continuous) @ 2000 PSI (140 Bar) .......... 1.7 GPM ....................... 6.4 L/min
Flow (Intermittent) @ 2000 PSI (140 Bar) ......... 1.7 GPM ....................... 6.4 L/min
Maximum Inlet Pressure ..................................... 145 PSI......................... 10 Bar
Plunger Diameter ................................................. 0.47”............................. 12 mm
Stroke................................................................... 0.25”............................. 6.3 mm
Max. Temperature of Pumped Fluids .................. 160o F............................ 70o C
Inlet Ports.................................................................................................... (2) 1/2" BSP
Discharge Ports........................................................................................... (2) 3/8" BSP
Shaft Rotation ...................................................... Top of Pulley Towards Fluid End
Crankshaft Diameter............................................ 0.98”............................. 24 mm
Key Width ........................................................... 0.31”............................. 8 mm
Shaft Mounting .................................................... Right Side Facing Manifold
Weight ................................................................. 11.7 lbs. ........................ 5.3 Kg
Crankcase Oil Capacity ....................................... 7.5 fl.oz. ....................... 0.22 Liters
Extended Crankcase Oil Capacity ....................... 9.0 fl.oz. ....................... 0.27 Liters
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:
The rating shown are the power
requirements for the pump. Gas
engine power outputs must be
approximately twice the pump
power requirements shown above.
P207 HORSEPOWER REQUIREMENTS
RPM GPM 1000 PSI 1500 PSI 2000 PSI 2500 PSI*
500 0.26
1000 0.51
1750 0.90
3000 1.48
3200 1.58
3450 1.70
0.2
0.4
0.6
1.0
1.1
1.2
0.3
0.5
0.9
1.5
1.6
1.8
0.4
0.7
1.2
2.0
2.2
2.3
0.4
0.9
1.6
2.6
2.7
2.9
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
5
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Specifications
Model P208
1750 RPM+
...................................................................................................
U. .S.
Metric
Flow (Continuous) @ 2000 PSI (140 Bar) .......... 1.0 GPM ....................... 3.8 L/min
Flow (Intermittent) @ 2500 PSI (175 Bar) ......... 1.0 GPM ....................... 3.8 L/min
3450 RPM+
Flow (Continuous) @ 2000 PSI (140 Bar) .......... 1.9 GPM ....................... 7.2 L/min
Flow (Intermittent) @ 2000 PSI (140 Bar) ......... 1.9 GPM ....................... 7.2 L/min
Maximum Inlet Pressure ..................................... 145 PSI......................... 10 Bar
Plunger Diameter ................................................. 0.47”............................. 12 mm
Stroke................................................................... 0.28”............................. 7 mm
Max. Temperature of Pumped Fluids .................. 160o F............................ 70o C
Inlet Ports.................................................................................................... (2) 1/2" BSP
Discharge Ports........................................................................................... (2) 3/8" BSP
Shaft Rotation ...................................................... Top of Pulley Towards Fluid End
Crankshaft Diameter............................................ 0.98”............................. 24 mm
Key Width ........................................................... 0.31”............................. 8 mm
Shaft Mounting .................................................... Right Side Facing Manifold
Weight ................................................................. 11.7 lbs. ........................ 5.3 Kg
Crankcase Oil Capacity ....................................... 7.5 fl.oz. ....................... 0.22 Liters
Extended Crankcase Oil Capacity ....................... 9.0 fl.oz. ....................... 0.27 Liters
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:
The rating shown are the power
requirements for the pump. Gas
engine power outputs must be
approximately twice the pump
power requirements shown above.
P208 HORSEPOWER REQUIREMENTS
RPM GPM 1000 PSI 1500 PSI 2000 PSI 2500 PSI*
250 0.14
500 0.29
1000 0.57
1750 1.00
3000 1.60
3200 1.80
3450 1.90
0.1
0.2
0.4
0.7
1.1
1.2
1.3
0.1
0.3
0.6
1.0
1.7
1.9
2.0
0.2
0.4
0.8
1.4
2.2
2.5
2.6
0.2
0.5
1.0
1.7
2.8
3.1
3.3
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
6
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Specifications
Model P209
1750 RPM+
...................................................................................................
U. .S.
Metric
Flow (Continuous) @ 2000 PSI (140 Bar) .......... 1.5 GPM ....................... 5.7 L/min
Flow (Intermittent) @ 2500 PSI (175 Bar) ......... 1.5 GPM ....................... 5.7 L/min
3450 RPM+
Flow (Continuous) @ 2000 PSI (140 Bar) .......... 2.7 GPM ....................... 10.2 L/min
Flow (Intermittent) @ 2000 PSI (140 Bar) ......... 2.7 GPM ....................... 10.2 L/min
Maximum Inlet Pressure ..................................... 145 PSI......................... 10 Bar
Plunger Diameter ................................................. 0.47” ............................. 12 mm
Stroke................................................................... 0.39” ............................. 10 mm
Max. Temperature of Pumped Fluids .................. 160o F............................ 70o C
Inlet Ports.................................................................................................... (2) 1/2" BSP
Discharge Ports........................................................................................... (2) 3/8" BSP
Shaft Rotation ...................................................... Top of Pulley Towards Fluid End
Crankshaft Diameter............................................ 0.98” ............................. 24 mm
Key Width ........................................................... 0.31” ............................. 8 mm
Shaft Mounting .................................................... Right Side Facing Manifold
Weight ................................................................. 11.7 lbs. ........................ 5.3 Kg
Crankcase Oil Capacity ....................................... 7.5 fl.oz. ....................... 0.22 Liters
Extended Crankcase Oil Capacity ....................... 9.0 fl.oz. ....................... 0.27 Liters
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:
P209 HORSEPOWER REQUIREMENTS
The rating shown are the power
RPM GPM 1000 PSI 1500 PSI 2000 PSI 2500 PSI*
requirements for the pump. Gas
500 0.43
1000 0.86
1750 1.50
3000 2.35
3200 2.50
3450 2.70
0.3
0.6
1.0
1.6
1.7
1.9
0.4
0.9
1.6
2.4
2.6
2.8
0.6
1.2
2.1
3.2
3.4
3.7
0.7
1.5
2.6
4.0
4.3
4.7
engine power outputs must be
approximately twice the pump
power requirements shown above.
We recommend a 1.15 service factor
be specified when selecting an
electricmotor 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 P210
1750 RPM+
...................................................................................................
U. .S.
Metric
Flow (Continuous) @ 2000 PSI (140 Bar) .......... 1.8 GPM ....................... 6.8 L/min
Flow (Intermittent) @ 2500 PSI (175 Bar) ......... 1.8 GPM ....................... 6.8 L/min
3450 RPM+
Flow (Continuous) @ 2000 PSI (140 Bar) .......... 3.3 GPM ....................... 12.5 L/min
Flow (Intermittent) @ 2000 PSI (140 Bar) ......... 3.3 GPM ....................... 12.5 L/min
Maximum Inlet Pressure ..................................... 145 PSI......................... 10 Bar
Plunger Diameter ................................................. 0.47” ............................. 12 mm
Stroke................................................................... 0.49” ............................. 12.4 mm
Max. Temperature of Pumped Fluids .................. 160o F............................ 70o C
Inlet Ports.................................................................................................... (2) 1/2" BSP
Discharge Ports........................................................................................... (2) 3/8" BSP
Shaft Rotation ...................................................... Top of Pulley Towards Fluid End
Crankshaft Diameter............................................ 0.98” ............................. 24 mm
Key Width ........................................................... 0.31” ............................. 8 mm
Shaft Mounting .................................................... Right Side Facing Manifold
Weight ................................................................. 11.7 lbs. ........................ 5.3 Kg
Crankcase Oil Capacity ....................................... 7.5 fl.oz. ....................... 0.22 Liters
Extended Crankcase Oil Capacity ....................... 9.0 fl.oz. ....................... 0.27 Liters
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:
P210 HORSEPOWER REQUIREMENTS
RPM GPM 1000 PSI 1500 PSI 2000 PSI 2500 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 0.26
500 0.51
1000 1.03
1750 1.80
3000 2.87
3200 3.06
3450 3.30
0.2
0.4
0.7
1.2
2.0
2.1
2.3
0.3
0.5
1.1
1.9
3.0
3.2
3.4
0.4
0.7
1.4
2.5
4.0
4.2
4.6
0.4
0.9
1.8
3.1
5.0
5.3
5.7
We recommend a 1.15 service factor
be specified when selecting an
electric motor as the power source.
To compute specific pump horse
power requirements, use the
following formula:
*Intermittent duty only
HP = (GPM X PSI) / 1450
8
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Specifications
Model P211
1750 RPM+
...................................................................................................
U. .S.
Metric
Flow (Continuous) @ 2000 PSI (140 Bar) .......... 2.1 GPM ....................... 7.9 L/min
Flow (Intermittent) @ 2500 PSI (175 Bar) ......... 2.1 GPM ....................... 7.9 L/min
3450 RPM+
Flow (Continuous) @ 2000 PSI (140 Bar) .......... 3.8 GPM ....................... 14.4 L/min
Flow (Intermittent) @ 2000 PSI (140 Bar) ......... 3.8 GPM ....................... 14.4 L/min
Maximum Inlet Pressure ..................................... 145 PSI......................... 10 Bar
Plunger Diameter ................................................. 0.47” ............................. 12 mm
Stroke................................................................... 0.56” ............................. 14.2 mm
Max. Temperature of Pumped Fluids .................. 160o F............................ 70o C
Inlet Ports.................................................................................................... (2) 1/2" BSP
Discharge Ports........................................................................................... (2) 3/8" BSP
Shaft Rotation ...................................................... Top of Pulley Towards Fluid End
Crankshaft Diameter............................................ 0.98” ............................. 24 mm
Key Width ........................................................... 0.31” ............................. 8 mm
Shaft Mounting .................................................... Right Side Facing Manifold
Weight ................................................................. 11.7 lbs. ........................ 5.3 Kg
Crankcase Oil Capacity ....................................... 7.5 fl.oz. ....................... 0.22 Liters
Extended Crankcase Oil Capacity ....................... 9.0 fl.oz. ....................... 0.27 Liters
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.
P211 HORSEPOWER REQUIREMENTS
RPM GPM 1000 PSI 1500 PSI 2000 PSI 2500 PSI*
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.
500 0.60
1000 1.20
1750 2.10
3000 3.30
3200 3.52
3450 3.80
0.4
0.8
1.4
2.3
2.4
2.6
0.6
1.2
2.2
3.4
3.6
3.9
0.8
1.7
2.9
4.6
4.9
5.2
1.0
2.1
3.6
5.7
6.1
6.5
We recommend a 1.15 service factor
be specified when selecting an
electricmotor as the power source.
To compute specific pump horse
power requirements, use the
following formula:
*Intermittent duty only
HP = (GPM X PSI) / 1450
9
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Exploded View - P205/P206/P207/P208/P209/P210/P211
10
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P205/P206/P207/P208/P209/P210/P211 PARTS LIST
ITEM PART NO. DESCRIPTION
QTY.
1
ITEM PART NO. DESCRIPTION
QTY.
1
14
06207
08333
06641
08442
Woodruff Key
1
08300
06773
08302
08302-L
07190
13262
08005
06273
08192
07188
01176-2
08303
08490
08492
07225
01166
08020
01020
06694
08465
06547
12258
08440
08466
08467
Crankcase
15
Connecting Rod
Plunger, Complete, 12mm
Wrist Pin
3
2
Oil Dipstick with O-Ring
Crankcase Cover, Short
Crankcase Cover, Long
Drain Plug
1
16
3
3
1
17
3
3
1
19
08356-0010 Oil Seal
3
3A
3B
4
1
20
06645
08443
07391
08598
07392
06646
06647
07849
07491
07906
07907
07853
07928
07946
07913
08316
13338
07661
07109
08486
Seal Case
3
Gasket for drain plug
O-Ring
1
21
O-Ring
3
1
23
V-Sleeve
3
5
Oil Drain Plug with Gasket
Gasket
1
23A
24
V-Sleeve, Weep
Support Ring
Weep Return Ring
Valve Casing
Valve Seat
3
5A
6
1
3
Screw, Short Cover
Spring Washer
4
25
3
6A
7
12
2
26
1
Bearing Cover I
Sight Glass
27
6
8
1
28
Valve Plate
6
9
O-Ring for Sight Glass
Screw with Lock Washer
Radial Shaft Seal
Ball Bearing
1
29
Valve Spring
Valve Spring Retainer
O-Ring
6
10
11
12A
12B
13
13
13
13
13
13
13
8
30
6
1
31
6
1
32
Valve Plug
6
Ball Bearing
1
32X
33
Valve Assembly Complete
O-Ring
6
Crankshaft (P205)
Crankshaft (P206)
Crankshaft (P207)
Crankshaft (P208)
Crankshaft (P209)
Crankshaft (P210)
Crankshaft (211)
1
6
1
34
Hex Head Cap Screw
Plug, 3/8" BSP
Seal
8
1
38
1
1
38A
39
1
1
Plug, 1/2" BSP
Copper Seal Ring
1
1
39A
1
1
11
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P205/P206/P207/P208/P209/P210/P211 REPAIR KITS
Plunger Packing Kit
Part # 09527
Oil Seal Kit
Part # 09144
Item # Part #
Item # Part # Description
Qty.
Description
Qty.
3
23
07391 V-Sleeve, weep 3
19
08356-0010 Oil Seal
23A
24
08598 V-Sleeve
07392 Support Ring
3
3
Valve Assembly Kit
Part # 09116
Item # Part # Description
Qty.
6
6
32X
31
07946 Valve Assembly Complete
07853 O-Ring
P205/P206/P207/P208/P210/P211 TORQUE SPECIFICATIONS
Position
Item#
07928
08316
Description
Torque Amount
59 (ft.-lbs.)
32
34
Valve Plug
Hex Head Cap Screw, Valve Casing
105 (in.-lbs.)
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”x W=1.00”x h=2.50”)
01161 - Plated Steel Channel Rails
(L=5.75”x W=1.00”x H=2.50”)
12
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REPAIR INSTRUCTIONS - P205/P206/P207/P208/P209/P210/P211 PUMPS
NOTE: Always take time to lubricate all metal and nonmetal parts with a light film of oil before reassembly.
This step will ensure proper fit, at the same time protecting the pump nonmetal parts (i.e., the elastomers) from cutting
and scoring.
1. With a 22mm socket
wrench, remove the (3)
discharge valve plugs and
(3) inlet valve plugs (32)
Inspect the o-ring (33) for
wear and replace if dam-
aged.
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).
4. Remove the o-ring (31).
Inspect all parts for wear
and replace as necessary.
For pumps manufactured
prior to 5/97, tighten plugs
(32) to 33 ft-lbs. otherwise,
apply one drop of Loctite
243 to the valve plugs (32)
and tighten to 59 ft.-lbs.
5. Next, use a 5mm allen
wrench to remove the 8
socket head cap screws
(34).
6. Carefully slide the valve
casing (26) out over the
plungers.
9. If the crankcase oil seals
(19) are to be replaced,
they can be removed by
first removing the crank-
shaft (13), connecting rod
(15), and plunger assem-
bly (16) from the gear end.
Then the oil seals can be
pushed out from the rear.
Please contact Giant for
details.
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!
7. Remove the weep return
ring (25), pressure ring
(24), and v-sleeve (23)
from the valve casing (26).
Remove the weep v-sleeve
(23A) from the seal case
(20).Inspect all parts,
including o-ring (21) for
wear and replace as
necessary.
13
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REPAIR INSTRUCTIONS - P205/P206/P207/P208/P209/P210/P211 PUMPS
NOTE: If there are
10. If the ceramic plunger pipe
(16) is damaged, replace
entire plunger assembly by
removing crankshaft (13).
Contact Giant for further
details.
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.
Reassembly sequence of the P205/P206/P207/P208/P209/P210/P211 PUMPS
1)
2)
3)
If oil seals (19) were removed, replace with seal lip towards crankcase. Lubricate seals before replacing.
Contact Giant for assistance with the reassembly of the gear end.
Replace seal case (20) with o-rings (21) over plungers. Generously lubricate o-rings and oil seal before
reassembly. Replace weep v-sleeve (23A) over plungers (16)..
Generously lubricate v-sleeve (23). Assemble v-sleeves (23) 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.
For maintenance of the gear end of your pump contact Giant Industries or your local distributor.
Phone: 419/531-4600
NOTE: Contact Giant Industries for Service School Information. Phone: (419)-531-4600
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 Gallon) p/n 1154
Seal Spare Parts (1 kit/pump)
(See page 12 for kit list)
X
X
X
X
Oil Seal Kit (1 kit/pump)
(See page 12 for kit lit)
Valve Spare Parts (1 kit/pump)
(See page 12 for kit list)
X
14
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P
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 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.
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 2007 Giant Industries, Inc.
07/07 P200_12mm.PM6
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