Triplex Ceramic

Series
Plunger Pump
Operating Instructions/
Repair and Service
Manual

P200-18mm versions
For Models:
P217
P218
P219
P220
P221
P227
P230

Contents: Page
Installation Instructions: 2
Pump Specifications: 3
Exploded View: 4
Parts List: 5
Repair Kits: 6
Pump System Troubleshooting: 7
Recommended Spare Parts List: 8
Pump Mounting Selection Guide: 8
Torque Specificiations: 8
Repair Instructions: 9-10
Updated 09/14 Dimensions: 11
Warranty Information: back page
 INSTALLATION INSTRUCTIONS
Installation of the Giant Industries, Inc., tions, and other system areas. The use of a
pump is not a complicated procedure, but dampener with Giant Industries, Inc. pumps
there are some basic steps common to all is optional, although recommended by Giant
pumps. The following information is to be Industries, Inc. to further reduce system pulsa-
considered as a general outline for instal- tion. Dampeners can also reduce the severity
lation. If you have unique requirements, of pressure spikes that occur in systems using
please contact Giant Industries, Inc. or your a shut-off gun. A dampener must be positioned
local distributor for assistance. downstream from the unloader.

1. The pump should be installed flat on a base 5. Crankshaft rotation on Giant Industries, Inc.
to a maximum of a 15 degree angle of inclina- pumps should be made in the direction desig-
tion to ensure optimum lubrication. nated by the arrows on the pump crankcase.
Reverse rotation may be safely achieved by
2. The inlet to the pump should be sized for following a few guidelines available upon
the flow rate of the pump with no unnecessary request from Giant Industries, Inc. Required
restrictions that can cause cavitation. Teflon horsepower for system operation can be ob-
tape should be used to seal all joints. If pumps tained from the charts on pages 3-9.
are to be operated at temperatures in excess of
1600 F, it is important to insure a positive head 6. Before beginning operation of your pumping
to the pump to prevent cavitation. system, remember: Check that the crankcase
and seal areas have been properly lubricated
Make sure that suction pulsation is sufficiently per recommended schedules. Do not run the
dampened - water column resonance must be pump dry for extended periods of time. Cavi-
avoided. tation will result in severe damage. Always
remember to check that all plumbing valves are
3. The discharge plumbing from the pump open and that pumped media can flow freely to
should be properly sized to the flow rate to the inlet of the pump.
prevent line pressure loss to the work area. It
is essential to provide a safety bypass valve Important! If there is a danger of frost, the
between the pump and the work area to protect water in the pump and in the pump fittings
the pump from pressure spikes in the event of (particularly the unloader valve) must be emp-
a blockage or the use of a shut-off gun. tied. The second discharge port can be used
4. Use of a dampener is necessary to minimize and the pump run “dry” for 1-2 minutes for this
pulsation at drive elements, plumbing, connec- purpose.

Finally, remember that high pressure operation in a pump system has many advantages. But, if it
is used carelessly and without regard to its potential hazard, it can cause serious injury.

IMPORTANT OPERATING CONDITIONS

Failure to comply with any of these conditions invalidates the warranty.
1. Prior to initial operation, add oil to the crank- 3. Acids, alkalines, or abrasive fluids cannot
case so that oil level is between the two lines be pumped unless approval in writing is ob-
on the oil dipstick. DO NOT OVERFILL. tained before operation from Giant Industries,
Inc.
Use Giant 20W-50 oil (p/n 01153)
4. Run the pump dry approximately 10 sec-
Crankcase oil should be changed after the onds to drain the water before exposure to
first 50 hours of operation, then at regular inter- freezing temperatures.
vals of 500 hours or less depending on operat-
ing conditions. 5. If there is danger of frost, the
water in the pump and in the pump fittings (par-
2. Pump operation must not exceed rated ticularly the unloader valve) must be emptied.
pressure, volume, or RPM. A pressure relief The second discharge port can also be used
device must be installed in the discharge of the and the pump run “dry” for 1-2 minutes for this
system. purpose.
2
 Pump Specifications
Max. Max. Nominal/ Nominal/ Max. Max. Max. Plunger Plunger Stroke Stroke Power Power
Flow Flow Intermittent Intermittent Speed Inlet Inlet Diameter Diameter Req’d Req’d
Pressure Pressure Pressure Pressure

Model GPM l/min PSI bar RPM PSI bar in mm in mm BHP kW

P230 1.1 4.2 2000/2500 140/172 1750 145 10 0.71 18 0.13 3.4 1.5/1.9 1.1/1.4
P217 1.8 6.8 2000/2500 140/172 1750 145 10 0.71 18 0.22 5.5 2.5/3.1 1.9/2.3
P230 2.0 7.8 2000/2500 140/172 3450* 145 10 0.71 18 0.13 3.4 2.8/3.5 2.1/2.6
P227 2.1 8.0 2000/2500 140/172 1750 145 10 0.71 18 0.25 6.3 2.9/3.6 2.2/2.7
P221 2.3 8.9 2000/2500 140/172 1750 145 10 0.71 18 0.28 7.0 3.2/4.0 2.4/3.0
P217 3.3 12.5 2000/2500 140/172 3450* 145 10 0.71 18 0.22 5.5 4.6/5.7 3.4/4.3
P218 3.4 12.9 2000/2500 140/172 1750 145 10 0.71 18 0.39 10.0 4.7/5.9 3.5/4.4
P227 3.8 14.4 2000/2500 140/172 3450* 145 10 0.71 18 0.25 6.3 5.2/6.6 3.9/4.9
P219 4.2 15.9 2000/2500 140/172 1750 145 10 0.71 18 0.49 12.4 5.8/7.2 4.3/5.4
P221 4.2 15.9 2000/2500 140/172 3450* 145 10 0.71 18 0.28 7.0 5.8/7.2 4.3/5.4
P220 4.7 17.8 2000/2500 140/172 1750 145 10 0.71 18 0.56 14.1 6.5/8.1 4.8/6.0
*
Positive inlet pressure required- Make sure that suction pulsation is sufficiently dampened-water column resonance must be avoided.

Common Specifications U.S. Metric

Max. Temperature of Pumped Fluids...................... 160o F** ................................................................. 71o 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 Liter
Extended Crankcase Oil Capacity.......................... 9.0 fl.oz.............................................................. 0.27 Liter
Volumetric Efficiency @ 1750 RPM........................................................................................................... 0.94
Volumetric Efficiency @ 3450 RPM........................................................................................................... 0.87
Mechanical Efficiency @ 3450 RPM......................................................................................................... 0.86
**For P200-HK pump the rating is 195o F (90o C) . Max. Pressure = 2000 PSI (140 bar)

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:
We recommend a 1.15 service factor be specified when selecting an electric motor as the power source.
To compute electric motor horsepower required, use the following formula: HP = (GPM X PSI) / 1450.
The formula to determine the horsepower required for a gas engine is: HP = (GPM X PSI) / 1150.
The formula to determine the horsepower required for a diesel engine is: HP = (GPM X PSI) / 1250.

For the Application of a Hydraulic Motor:

To Determine the Torque of a Hydraulic Motor -- (GPM x PSI x 36.77) / RPM = Torque (in-lbs)

Calculating RPM / GPM of Pump:

A pump must be connected to an electric motor or gas or diesel engine with the correct ratio of pulleys
and belts to attain the required speed and GPM. The use of a Variable Frequency Drive (VFD) may also
be used to control the RPM of a properly sized electric motor when variable flows are required.
(Max. Pump RPM / Rated Pump GPM) x Required Pump GPM = Required Pump RPM
To calculate a pulley diameter one (1) pulley diameter and the required pump RPM must be known:
(Pump RPM x Pump Pulley Diameter) / Motor RPM = Motor Pulley Diameter
(Motor RPM x Motor Pulley Diameter) / Pump RPM = Pump Pulley Diameter

3
 Exploded View
P217/P218/P219/P220/P221/P227/P230

4
 Spare Parts
P217/P218/P219/P220/P221/P227/P230

ITEM PART NO. DESCRIPTION QTY. ITEM PART NO. DESCRIPTION QTY.
1 08300 Crankcase 1 16A 08468 Plunger Base 3
2 06773 Oil Dipstick with O-Ring 1 16B 08455 Plunger Pipe 3
3 08302 Crankcase Cover, Short 1 16C 08456 Tension Screw 3
3 08302-L Crancase Cover, Long 1 16D 07676 Copper Gasket 3
3A 07190 Drain Plug & Gasket 1 17 08442 Wrist Pin 3
4 08005 O-Ring 1 18 07770 O-Ring 3
5 06273 Oil Drain Plug 1 19 08356 Oil Seal 3
5A 08192 Gasket 1 20 08444 Seal Case 3
6 07188 Screw, Crankcase Cover 4 21 08443 O-Ring 3
6A 01176-2 Spring Washer 4 23 08477 V-Sleeve, Weep 3
7 08303 Bearing Cover I 2 23A 08087 V-Sleeve, Brown 3
8 08490 Sight Glass 1 24 07904 Pressure Ring 3
9 08492 O-Ring for Sight Glass 1 25 08445 Weep Return Ring 3
10 07225 Screw with Lock Washer 8 26 06582+ Valve Casing 1/2” Inlet Ports 1
11 01166 Radial Shaft Seal 1 27 07849 Valve Seat 6
12A 08020 Ball Bearing 1 28 07491 Valve Plate 6
12B 01020 Ball Bearing 1 29 07906 Valve Spring 6
13 08465 Crankshaft (P217) 1 30 07907 Valve Spring Retainer 6
13 08440 Crankshaft (P218) 1 31 07853 O-Ring 6
13 08466 Crankshaft (P219) 1 32 07928 Valve Plug 6
13 08467 Crankshaft (P220) 1 32X 07946A Valve Assembly Complete 6
13 12258 Crankshaft (P221) 1 33 07913 O-Ring 6
13 06547 Crankshaft (P227) 1 34 08316 Hex Head Cap Screw 8
13 06694 Crankshaft (P230) 1 38 13338 Plug, 3/8” BSP 1
14 06207 Woodruff Key 1 38A 08486 Copper Crush Washer, 3/8” 1
15 08333 Connecting Rod 3 39 07109 Plug, 1/2” BSP 1
16 08469 Plunger, Complete, 18mm 3 39A 07661 Seal 1

5
 Repair Kits
P217/P218/P219/P220/P221/P227/P230
Plunger Packing Kit Optional Kits
Part # 09164
Item # Part # Description Qty. Teflon Plunger Packing Kit
23 08477 V-Sleeve, Weep 3 Part # 09164-0021
23A 08087 V-Sleeve, Brown 3 Item # Part # Description Qty.
24 07904 Pressure Ring 3 18 07770-0001 O-Ring, Viton 3
21 08443-0001 O-Ring, Viton 3
Valve Assembly Kit 23/23A 08087-0020 Weep Seal, Teflon 6
Part # 09116 24 07904 Pressure Ring 3
Item # Part # Description Qty. 31 07853-0001 O-Ring, Viton 6
32X 07946A Valve Assembly Complete 6 33 07913-0001 O-Ring, Viton 6
31 07853 O-Ring 6
33 07913 O-Ring 6 Viton Seal Kit
# 09164-0011
Oil Seal Kit Item Part # Description Qty.
Part # 09144 18 07770-0001 O-Ring, Viton 3
Item # Part # Description Qty. 21 08443-0001 O-Ring, Viton 3
19 08356-0010 Oil Seal 3 23 08087-0010 V-Sleeve 6
24 07904 Pressure Ring 3
31 07853-0001 O-Ring, Viton 6
33 07913-0001 O-Ring, Viton 6

High Temperature Seal Kit

# 09599
Item Part # Description Qty.
23/23A 08477-0030 High-Temp Seal 6
24 07904 Pressure Ring 6+

+ Kit contains six (6) pressure rings. Only three (3)

are required for the P200 Series Pumps.

6
 PUMP SYSTEM MALFUNCTION

MALFUNCTION CAUSE REMEDY

The Pressure and/

Worn packing seals Replace packing seals
or the Delivery
Broken valve spring Replace spring
Drops
Belt slippage Tighten or Replace belt
Worn or Damaged nozzle Replace nozzle
Fouled discharge valve Clean valve assembly
Fouled inlet strainer Clean strainer
Worn or Damaged hose Repair/Replace hose
Worn or Plugged relief valve on pump Clean, Reset, and Replace worn parts
Cavitation Check suction lines on inlet of
pump for restrictions
Unloader Check for proper operation

Water in crankcase High humidity Reduce oil change interval

Worn seals Replace seals

Noisy Operation Worn bearings Replace bearings, Refill crankcase

oil with recommended lubricant
Cavitation Check inlet lines for restrictions
and/or proper sizing

Rough/Pulsating Worn packing Replace packing

Operation with Inlet restriction Check system for stoppage, air Pres-
sure Drop leaks, correctly sized inlet
plumbing to pump
Accumulator pressure Recharge/Replace accumulator
Unloader Check for proper operation
Cavitation Check inlet lines for restrictions
and/or proper size

Pump Pressure as Restricted discharge plumbing Re-size discharge plumbing to

Rated, Pressure flow rate of pump
Drop at gun

Excessive Worn plungers Replace plungers
Leakage Worn packing/seals Adjust or Replace packing seals
Excessive vacuum Reduce suction vacuum
Cracked plungers Replace plungers
Inlet pressure too high Reduce inlet pressure

High Crankcase Wrong Grade of oil Giant oil is recommended

Temperature Improper amount of oil in crankcase Adjust oil level to proper amount

7
Preventative Maintenance Check List & Recommended Spare
Parts List
Preventative Maintenance Check List & Recommended Spare Parts List
Every Every Every
Check Daily Weekly 50 Hrs. 500 Hrs 1500 Hrs 3000 Hrs
Oil Level/Quality X
Oil Leaks X
Water Leaks X
Belts, Puelly X
Plumbing X
Recommended Spare Parts
Oil Change
(1 quart)
(1 gallon)p/n
p/n01153
01154 X X
Plunger Seal Kit
(1 kit/pump) X
Oil Seal Kit
(1 kit/pump) X
Inlet and
Valve Valve Repair
Assembly
Kit (1 kit/pump) X
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”)

Torque Specifications
Position Item# Description Torque Amount
16C 08456 Tension Screw, Plunger 200 in.-lbs. (22.5 Nm)
32 07928 Valve Plug 55 ft.-lbs. (75 Nm)
34 08316 Hex Head Cap Screw, Valve Casing 106 in.-lbs. (12 Nm)

8
 REPAIR INSTRUCTIONS - P217/P218/P219/P220/P221/P227/P230 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 2. Using a needle nose 3. By inserting a small

wrench, remove the (3) pliers, remove the inlet screw driver between
discharge valve plugs and discharge valve as- the valve seat (27) and
and (3) inlet valve plugs semblies (32X). the valve spring retainer
(32) Inspect the o-ring (30), the valve assembly
(33) for wear and re- can be separated.
place if damaged.

4. Remove the o-ring (31). 5. Next, use a 5mm allen 6. Carefully slide the valve
Inspect all parts for wear wrench to remove the 8 casing (26) out over the
and replace as neces- socket head cap screws plungers.
sary. Apply one drop of (34).
Loctite 243 to the valve
plugs (32) and tighten to
55 ft.-lbs. (75 Nm)

8. Check surfaces of
plunger (16). A dam-
aged surface will cause
accelerated wear on
the seals. Deposits of
any kind must be care-
fully removed from the
plunger surface. A dam-
aged plunger must be
replaced!

7. Remove the weep return 9. If the crankcase oil

ring (25), pressure ring seals (19) are to be re-
(24), and v-sleeve (23) placed, they can be re-
from the valve cas- moved by prying loose
ing (26). Remove the with a flat screwdriver.
v-sleeve (23A) from the Take care not to make
seal case (20). Inspect contact with the plunger.
all parts, including o-ring
(21) for wear and re- 9
place as necessary
REPAIR INSTRUCTIONS - P217/P218/P219/P220/P221/P227/P230 PUMPS

10. If the ceramic plunger

pipe (16B) is damaged, NOTE: If there are
remove the plunger bolt deposits of any kind
(16C). Discard the old (i.e., lime deposits) in
plunger pipe (16B) and the valve casing, be
copper gasket (16D), certain that the weep
and clean the old lock- holes in the weep
tite from the plunger return ring (25) and
bolt (16C) and plunger valve casing (26) have
base (16A). Replace not been plugged.
the plunger with the
new one and locktite the
plunger bolt and torque
to 200 in.-lbs. (22.5 Nm)

Reassembly sequence of the P217/P218/P219/P220/P221/P227/P230

pumps
1) If oil seals (19) were removed, replace with seal lip towards crankcase. Lubricate seals
before replacing.

2) 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). As-
semble 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
106 inch-pounds (12 Nm) 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). 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 55 ft.-lbs. (75
Nm).

NOTE: Contact Giant Industries for Service School Information. Phone: (419)-531-4600

10
 Dimensions - Inches (mm)
P217/P218/P219/P220/P221/P227/P230

11
 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 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.

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 work-
manship 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 war-
ranty 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-
ranties 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
Phone: (419)-531-4600 FAX (419)-531-6836, www.giantpumps.com
 Copyright 2014 Giant Industries, Inc.

10/14 P200-18mm.indd