Giant Water Pump CP200 User Manual

Triplex Ceramic  
Plunger Pump  
OperatingInstructions/  
Repair and Service  
Manual  
Series  
CP200  
For Models:  
CP218  
CP220  
CP230  
Contents:  
InstallationInstructions:  
PumpSpecifications:  
Exploded View:  
page 2  
pages 3-5  
page 6  
PartsList::  
page 7  
Recommended Spare  
Kits & Torque Specifications: page 8  
PumpMountingSelection  
Guide:  
page 8  
pages 9-10  
page 11  
RepairInstructions:  
TroubleShooting:  
Preventative  
Maintenance:  
Dimensions:  
WarrantyInformation:  
page 11  
back page  
back page  
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Specifications  
Model CP218  
Ratings ........................................................................................................ 1.4 GPM @ 2030 PSI  
Inlet Pressure.............................................................................................. 14 to 140 PSI  
RPM ........................................................................................................... Up to 750 RPM  
Plunger Diameter........................................................................................ 18mm  
Stroke.......................................................................................................... 10mm  
Temperature of Pumped Fluids................................................................... -40oF to 160oF  
Inlet Ports ................................................................................................... (2) 3/8" BSP  
Discharge Ports .......................................................................................... (2) 3/8" BSP  
Shaft Rotation ................................................................................ Top of PulleyTowards 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.  
+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  
CP218 HORSEPOWER REQUIREMENTS  
requirements for the pump. Gas  
engine power outputs must be  
approximately twice the pump  
power requirements shown above.  
RPM GPM 500 PSI 1000 PSI 1500 PSI 2030 PSI  
200 0.4  
300 0.6  
400 0.7  
500 0.9  
600 1.1  
750 1.4  
0.1  
0.2  
0.2  
0.3  
0.4  
0.5  
0.3  
0.4  
0.5  
0.6  
0.8  
1.0  
0.4  
0.6  
0.7  
0.9  
1.1  
1.4  
0.6  
0.8  
1.0  
1.3  
1.5  
2.0  
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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Specifications  
Model CP220  
Ratings ........................................................................................................ 1.9 GPM @ 2030 PSI  
Inlet Pressure.............................................................................................. 14 to 140 PSI  
RPM ........................................................................................................... Up to 750 RPM  
Plunger Diameter........................................................................................ 18mm  
Stroke.......................................................................................................... -40o 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.  
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  
CP220 HORSEPOWER REQUIREMENTS  
engine power outputs must be  
approximately twice the pump  
power requirements shown above.  
RPM GPM 500 PSI 1000 PSI 1500 PSI 2030 PSI  
200 0.5  
300 0.8  
400 1.0  
500 1.3  
600 1.5  
750 1.9  
0.2  
0.3  
0.3  
0.4  
0.5  
0.7  
0.3  
0.6  
0.7  
0.9  
1.0  
1.3  
0.5  
0.8  
1.0  
1.3  
1.6  
2.0  
0.7  
1.1  
1.4  
1.8  
2.1  
2.7  
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:  
HP = (GPM X PSI) / 1450  
4
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Specifications  
Model CP230  
Ratings ........................................................................................................ 0.5 GPM @ 2030 PSI  
Inlet Pressure.............................................................................................. 14 to 140 PSI  
RPM ........................................................................................................... Up to 750 RPM  
Plunger Diameter........................................................................................ 18mm  
Stroke.......................................................................................................... 3.4mm  
Temperature of Pumped Fluids................................................................... -40o 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.  
+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  
CP230 HORSEPOWER REQUIREMENTS  
RPM GPM 500 PSI 1000 PSI 1500 PSI 2030 PSI  
200 0.1  
300 0.2  
400 0.3  
500 0.3  
600 0.4  
750 0.5  
0.0  
0.1  
0.1  
0.1  
0.1  
0.2  
0.1  
0.1  
0.2  
0.2  
0.3  
0.3  
0.1  
0.2  
0.3  
0.3  
0.4  
0.5  
0.1  
0.3  
0.4  
0.4  
0.6  
0.7  
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  
5
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Exploded View  
CP200 Series  
6
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Spare Parts  
CP200 Series  
ITEM PARTNO. DESCRIPTION  
QTY.  
ITEM PARTNO. DESCRIPTION  
QTY.  
1
08300  
06773  
08302  
08302-L  
07190  
08005  
06273  
08192  
07188  
Crankcase  
1
16C  
16D  
16D  
16E  
17  
08456  
07676  
Tension Screw  
CopperGasket  
3
3
3
2
OilDipstickwithO-Ring  
Crankcase Cover, Short  
Crancase Cover, Long  
Drain Plug & Gasket  
O-Ring  
1
3
1
07204-0100 Copper Gasket(CP230only)  
3
1
06823  
08442  
07770  
PlungerExtension(CP230only) 3  
3A  
4
1
Wrist Pin  
O-Ring  
3
3
3
3
3
3
3
3
3
1
6
6
6
6
3
6
6
6
6
8
1
1
18  
5
OilDrainPlug  
1
19  
08356-0010 OilSeal  
5A  
6
Gasket  
1
20  
08444  
06815  
08087  
Seal Case  
Screw,CrankcaseCover  
4
21  
O-Ring  
6A  
7
07223-0100 Spring Washer  
4
23  
V-Sleeve,Weep  
08303  
08490  
08492  
07225  
01166  
08020  
01020  
08440  
08467  
06694  
06207  
08333  
08469  
08468  
08455  
Bearing Cover I  
OilSightGlass  
2
23A  
24  
08087-0020 V-Sleeve,Teflon  
8
1
07904  
08445  
08446  
07849  
06809  
06816  
07907  
06824  
06817  
07928  
06825  
06818  
08316  
13338  
Pressure Ring  
Weep Return Ring  
ValveCasing  
9
O-Ring  
1
25  
10  
11  
12A  
12B  
13  
13  
13  
14  
15  
16  
16A  
16B  
Screw with Lock Washer  
RadialShaftSeal  
BallBearing  
8
26  
1
27  
ValveSeat  
1
28  
ValvePlate  
BallBearing  
1
29  
ValveSpring  
Crankshaft(CP218)  
Crankshaft(CP220)  
Crankshaft(CP230)  
Woodruff Key  
1
30  
ValveSpringRetainer  
SpacerRing(CP230only)  
O-Ring  
1
30A  
31  
1
1
32  
ValvePlug  
Connecting Rod  
Plunger,Complete,18mm  
Plunger Base  
3
32X  
33  
Valve Assembly  
O-Ring  
3
3
34  
HexHeadCapScrew  
Plug, 3/8"BSP  
PlungerPipe  
3
38  
7
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Repair Kits  
CP200 Series  
Oil Seal Kit  
Plunger Packing Kit  
Part # 09144  
Part # 09554  
Item # Part #  
Description  
Qty.  
3
Item # Part #  
Description  
Qty.  
3
19  
08356-0010 Oil Seal  
23  
08087  
V-Sleeve, weep  
23A  
24  
08087-0020 V-Sleeve, brown  
07904 Pressure Ring  
3
3
Valve Assembly Kit  
Part # 09556  
Item # Part # Description  
Qty.  
6
6
6
6
27  
28  
29  
30  
31  
07849 Valve Seat  
06809 Valve Plate  
06816 Valve Spring  
07907 Valve Spring Retainer  
06817 O-Ring  
6
Pump Torque Specifications  
CP200 Series  
Position  
Item#  
08456  
07928  
08316  
Description  
Torque Amount  
16C  
32  
Tension Screw, Plunger  
Valve Plug  
220 (in.-lbs.)  
59 (ft.-lbs.)  
105 (in.-lbs.)  
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”)  
8
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REPAIR INSTRUCTIONS - CP200 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  
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  
(27-31).  
damaged.  
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.  
Remove the v-sleeve  
(23A) from the seal case  
(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).  
The spacer ring (30A) on  
CP230 pumps may remain  
inside the valve casing.  
9
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REPAIR INSTRUCTIONS - CP200  
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.  
10. If the ceramic plunger pipe  
(16B) is damaged, remove  
the plunger bolt (16C) and  
plunger extension (16E-  
CP230 only). Discard the  
old plunger pipe (16B)  
and copper gasket (16D).  
Clean the old locktite from  
the plunger bolt (16C) and  
plunger base (16A).  
Replace the plunger pipe,  
plunger extension (16E-  
(P230 only) and locktite the  
plunger bolt and torque to  
220 inch-pounds. Make  
sure you use a new  
gasket (16D) with the  
plunger bolt.  
Reassembly sequence of the CP200 pumps  
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). Make sure spacer  
ring (30E - CP230 pumps only) is present in the valve casing. 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.  
NOTE: Contact Giant Industries for Service School Information. Phone: (419)-531-4600  
10  
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PUMPSYSTEMMALFUNCTION  
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  
Replacenozzle  
Worn or Damaged nozzle  
Fouled discharge valve  
Fouled inlet strainer  
Worn or Damaged hose  
Worn or Plugged relief valve on pump  
Cavitation  
Clean valve assembly  
Cleanstrainer  
Repair/Replace hose  
Clean, Reset, and Replace worn parts  
Check suction lines on inlet of  
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  
oilwith  
Cavitation  
Replacebearings,Refillcrankcase  
recommended lubricant  
Check inlet lines for restrictions  
and/or proper sizing  
Rough/Pulsating  
Operation with  
Pressure Drop  
Worn packing  
Inlet restriction  
Replacepacking  
Check system for stoppage, air  
leaks, correctly sized inlet  
plumbing to pump  
Accumulator pressure  
Unloader  
Cavitation  
Recharge/Replaceaccumulator  
Check for proper operation  
Check inlet lines for restrictions  
and/or proper size  
Pump Pressure as  
gun  
Pressure  
Restricted discharge plumbing  
Re-size discharge plumbing to Drop at  
flow rate of pump  
Rated,  
Excessive  
Leakage  
Worn plungers  
Replace plungers  
Worn packing/seals  
Excessivevacuum  
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 (1 Quart) p/n 1153  
Seal Spare Parts (1 kit/pump)  
(See page 8 for kit list)  
Oil Seal Kit (1 kit/pump)  
(See page 8 for kit lit)  
X
X
X
X
Valve Spare Parts (1 kit/pump)  
(See page 8 for kit list)  
X
11  
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CP200 SERIES DIMENSIONS (inches)  
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.  
4/02CP200.PM6  
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