Giant P200A-5100 User's Manual
Contents
1. 2 3 8 BSP Inlet Ports P22 1TA S TOO cistitis ii ia 2 1 2 BSP Discharge POrts es ccessadeassieevassdusceansetees SEENEN 2 3 8 BSP Shatt et Top of Pulley Towards Fluid End Crankshaft Diameter T 24mm e Te T ll iii trial iils 8mm Shat MOUNN EE Right Side Facing Manifold A costes Saausdesnseceon teeters H lbs Ulm icons arseen 5 kg Crankcase Oil Capacity eee ee To E 0 2 liter Extended Crankcase Oil Capacity GA 0 3 liter Volumetric Efficiency 1750 RPM nnen nono veene enn 0 95 Volumetric Efficiency 3450 RPM nnen veen veenv enn 0 87 Mechanical Efficiency 1750 RPM neen venn 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 The rating shown are the power REQUIREMENTS requirements for the pump Gas IRPM GPM 1000 PSI 1500 PSI 2000 PSI engine power outputs must be E f app2. 4 2 107 1 4 36 1 18 30 8mm Wide Key DIN 6888 LOS ete ON mal Kaes nal i 0 8 4x M8 distance belween feel 4 7 119 e 3 9 99 Discharge Connection 3 8 BSP 3 8 P200 3100 Series 1 2 P200 5100 Series Inlet Connection 2 2 56 5 7 145 7 9 200 Short 9 2 234 Long 15 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 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
3. 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 2005 Giant Industries Inc 3 05 P200A 3100_5100 PMD
4. P Shaft Rotation rss versesnssorrerservenenseesntnenenssnrde Top of Pulley Towards Fluid End Crankshaft Diameter nennen AAA 24mm Key Width srssorssvrrseeorsesorsersensenrsennseernaatesseinn d AE 8mm Shaft MOUNDS irritar ieseinatersedeateeasenctestesstessuetieseestinn Either Side Weights tninn 11 lbs 110z 4 9 kg Crankcase Oil Capacity sesa zts vtzsyys strog aes E 0 24 liters Volumetric Efficiency E 1750 RPM eeen 0 96 Mechanical Efficiency 1750 RPM enen 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 Pulley selection and pump speed are based on a 1725 RPM motor and B section belts When selecting desired GPM allow for a 5 tolerance on pumps output due to variations in pulleys belts and motors among manufacturers 1 Select GPM required then select appropriate motor and pump pulley from the same line 2 The desired pressure is achieved by selecting the correct nozzle size that corresponds with the pump GPM HORSEPOWER INFORMATION Horsepower ratings shown are the power require ments for the pump Gas engine power outputs must be approximately twice the pump power require ments shown above We recommend that a 1 1 service factor be specified when selecting an electric motor as the power source To compute specific pump horsepower requirements use the following formul
5. Plug Cover 1 20 08444 0100 Seal Retainer 316 S S 3 Drain Plug amp Gasket 1 21 12260 0001 O Ring 3100 pumps 3 O Ring 1 21 08443 O Ring 5100 pumps 3 Oil Drain Plug with seal 1 23 08477 Grooved Seal 3 Screw 316 S S 4 23A 08087 Grooved Seal Ring Brown 3 Spring Washer 316 S S 4 23B 06163 Drip Shield 3 Bearing Cover I 2 24 07904 Pressure Ring 3 Sight Glass 1 25 08445 0100 Weep Return Ring 316 S S 3 O Ring 1 26 06582 3000 Valve Casing 3100 pumps 1 Screw 8 26 06582 5000 Valve Casing 5100 pumps 1 Spring Washer 8 27 07849 0100 Valve Seat 6 Radial Shaft Seal 1 28 07491 0100 Valve Plate 6 Ball Bearing 1 29 07906 0100 Valve Spring 6 Ball Bearing 1 30 07907 Valve Spring Retainer 6 Crankshaft P217A 3100 5100 1 31 7853 0001 O Ring 3100 pumps 6 Crankshaft P218A 3100 5100 1 31 07853 O Ring 5100 pumps 6 Crankshaft P219A 3100 5100 1 32 07928 0100 Plug 6 Crankshaft P220A 3100 5100 1 33 07913 0001 O Ring 3100 pumps 6 Crankshaft P221A 3100 5100 1 33 07913 O Ring 5100 pumps 6 Crankshaft P227A 3100 5100 1 34 08316 0100 Hex Head Cap Screw 8 Crankshaft P230A 3100 5100 1 36 13338 0300 Plug 3 8 3100 pumps 1 Woodruff Key 1 36 13338 0100 Plug 3 8 5100 pumps 1 Connecting Rod 3 36A 08486 Copper Washer 3 8 Plunger Complete 18mm 3 3100 pumps only 1 Plunger Base 316 S S 3 37 07109 0300 Plug 1 2 3100 pumps 1 Plunger 3 37 07109 0100 Plu
6. RPM motor and B section belts When selecting desired GPM allow for a 5 tolerance on pumps output due to variations in pulleys belts and motors among manufacturers 1 Select GPM required then select appropriate motor and pump pulley from the same line 2 The desired pressure is achieved by selecting the correct nozzle size that corresponds with the pump GPM HORSEPOWER INFORMATION Horsepower ratings shown are the power require ments for the pump Gas engine power outputs must be approximately twice the pump power require ments shown above We recommend that a 1 1 service factor be specified when selecting an electric motor as the power source To compute specific pump horsepower requirements use the following formula GPM X PSL _ 1450 TP P218A 3100 5100 PULLEY SELECTION amp HORSEPOWER REQUIREMENTS PUMP MOTOR PULLEY PULLEY npu GPM 800 PSI 1200 PSI 1500 PSI 1700 PSI 2000 PSI 1750 Specifications Model P219A 3100 5100 U S Metric MO 4 2 GPM eesse 15 9 LPM Discharge Pressure nennen ennen 2000 PSI vssdraagssc 140 bar Inlet PFESSUTE usina id OPS msc 6 2 bar REN E NN Up to 1750 RPM Plunger Diameter 4 TO seirinin 18mm SOKE sadaa Stegen O IAS enten 12 4mm Temperature of Pumped Fluids LOO EE 71 C Inlet Ports P219A 3100 annen Inlet Ports P219A 5100 anne See Eed 2 3 8 BSP ideas 2 1 2 BSP Discharge POTS urna iia 2 3 8 BS
7. Series P200A 3100 5100 Aluminum Bronze Models P221 3100 P227 3100 P230 3100 P217 3100 P218 3100 P219 3100 P220 3100 Triplex Ceramic Plunger Pump Operating Instructions Repair and Service Manual 316 S S Models P217 5100 P221 5100 P218 5100 P227 5100 P219 5100 P230 5100 P220 5100 Updated 3 05 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 Warranty Information page 2 pages 3 9 page 10 page 11 page 11 pages 12 13 page 13 page 14 page 15 back page INSTALLATION INSTRUCTIONS Installation of the Giant Industries Inc pump is not a complicated procedure but there are some basic steps common to all pumps The following information is to be considered as a general outline for installa tion If you have unique requirements please contact Giant Industries Inc or your local distributor for assistance 1 The pump should be installed flat on a base to a maximum of a 15 degree angle of inclination to ensure optimum lubrication 2 The inlet to the pump should be sized for the flow rate of the pump with no unnecessary restrictions that can cause cavitation Teflon tape should be used to seal all joints If pumps are to be operated at temperatures in excess of 160 F it
8. a GPM X PSI _ 1450 TP P219A 3100 5100 PULLEY SELECTION amp HORSEPOWER REQUIREMENTS PUMP MOTOR PULLEY PULLEY RPM GPM 800 PSI 1200 PSI 1500 PSI 1700 PSI 2000 PSI 1150 1750 Specifications Model P220A 3100 5100 U S Metric Viel UE 47GPM ou ececeeeees 17 8 LPM Discharge Pressure nennen ennen 2000 PSI sassazrastsa 140 bar Inlet S needed OO TEE 6 2 bar RPM WE 1750 RPM Plunger Diameter 4 TO secesesistesvutbeivseles 18mm SOKE A retara O SS E iesktivess 14 1mm Temperature of Pumped Fluids LOO EE 71 C Inlet Ports P220A 3100 esse ee eee Inlet Ports P220A 5100 sees eee verhaart 2 3 8 BSP Paysans aeiee 2 1 2 BSP Discharge POTIS T 2 3 8 BSP Shaft Rotation rss verres sorrenservenenseesntnanensserde Top of Pulley Towards Fluid End Crankshaft Diameter nennen AAA 24mm Key Width jsiccsciscecessscesesesectesisccesesssgecvnnasiezesi es d AE 8mm Shaft MOUNDS irritar cis delicia Either Side Weights tninn 11 lbs 110z 4 9 kg Crankcase Oil Capacity sesa zts vtssyys strog aes E 0 24 liters Volumetric Efficiency E 1750 RPM eeen 0 96 Mechanical Efficiency 1750 RPM enen 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 Pulley selection and pump speed are based on
9. a 1725 RPM motor and B section belts When selecting desired GPM allow for a 5 tolerance on pumps output due to variations in pulleys belts and motors among manufacturers 1 Select GPM required then select appropriate motor and pump pulley from the same line 2 The desired pressure is achieved by selecting the correct nozzle size that corresponds with the pump GPM HORSEPOWER INFORMATION Horsepower ratings shown are the power require ments for the pump Gas engine power outputs must be approximately twice the pump power require ments shown above We recommend that a 1 1 service factor be specified when selecting an electric motor as the power source To compute specific pump horsepower requirements use the following formula GPM X PSI _ 1450 TP P220A 3100 5100 PULLEY SELECTION amp HORSEPOWER REQUIREMENTS PUMP MOTOR Puntey puut Perm 00 si 1200 Ps 1500 Ps 170 Psi 2000 PSI 1150 1750 Specifications Model P221A 3100 5100 U S Metric 1750 RPM RANE S reer sains naiaiae rs 2 34 GPM 2000 PSI 8 9 LPM 137 bar 3450 RPM ELT 4 2 GPM 2000 PSI 15 9 LPM 137 bar Inlet Pressure sn vasserveesernstetnrrntenndrndsanede 4 35 to 140 PSI 0 3 to 10 bar RP Misato teens en dio Up to 3450 RPM Plunger Diameter ennen ORAA KEE E ET 18mm rn UE 7 0mm Temperature of Pumped Fluids Upto J60 F price 71 C Inlet Ports P22 1A 3 L
10. all plumbing valves are open and that pumped media can flow freely to the inlet of the pump 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 crankcase so that oil level is between the two lines on the oil dipstick DO NOT OVERFILL Use Giant recommened Oil Crankcase oil should be changed after the first 50 hours of operation then at regular intervals of 500 hours or less depending on operating conditions 2 Pump operation must not exceed rated pressure volume or RPM A pressure relief device must be installed in the discharge of the system 3 Acids alkalines or abrasive fluids cannot be pumped unless approval in writing is obtained before operation from Giant Industries Inc 4 Run the pump dry approximately 10 seconds to drain the water before exposure to freezing temperatures Specifications Model P217A 3100 5100 U S Metric 1750 RPM RANGES E 1 8 GPM E 2000 PSI 6 8 LPM 137 bar 3450 RPM Rato ios iio potes 3 3 GPM 2000 PSI 12 5 LPM 137 bar Plunger Diameter annen ereen vennen AO pijas 18mm STORE iia kluun dei EEEE EE VAD redduevondeeneingen cnica 5 5mm Temperature of Pumped Fl
11. ankcase oil with recommended lubricant Cavitation Check inlet lines for restrictions and or proper sizing Rough Pulsating Worn packing Replace packing Operation with Pressure Drop Pressure Drop at Gun Inlet restriction Accumulator pressure Unloader Cavitation Restricted discharge plumbing Check system for stoppage air leaks correctly sized inlet plumbing to pump Recharge Replace accumulator Check for proper operation Check inlet lines for restrictions and or proper size Re size discharge plumbing to flow rate of pump 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 Preventative Maintenance Check List amp Recommended Spare Parts List Oil Level Quality Daily Weekly 50hrs Every 500 hrs Every 1500 hrs Every 3000 hrs Oil Leaks Water Leaks Belts Pulley X Plumbing 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 14 P200A 3100 5100 DIMENSIONS INCHES mm
12. at 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 RATI P230 3100 5100 HORSEPOWER SC o See SE REQUIREMENTS requirements for the pump Gas GPM 1000 PSI 1500 PSI 2000 PSI engi gine power outputs must be 1000 power requirements shown above taso o9 os 09 13 We recommend a 1 15 service factor 1750 1 1 1 1 1 5 1750 11 08 11 15 ene u 3000 3200 electric motor as the power source 3450 To compute specific pump horse power requirements use the following formula HP GPM X PSI 1450 Exploded View P200A 3100 5100 Series Z i Hi S Cr O CH CA CH CJ Ca Mm Di eg oe E S a Le Ge SS e UDI A Ka CHH a eh 1 7 a RS Des 7 lt a 2A e 7 Be cht 36AT ES E CNS e E 37 7A o 20 Y 238 23A ITEM PART NO P200A 3100 5100 SERIES PARTS LIST 1 08300 2 08301 3 08302 3A 07190 0100 4 08005 5 08185 0100 6 07188 0100 6A 07223 0100 T 08303 8 08490 9 08492 10 07225 0100 10A 07223 0100 11 01166 12A 08020 12B 01020 13 08465 13 08440 13 08466 13 08467 13 12258 13 06547 13 06694 14 06207 15 08333 16 08469 0100 16A 08468 0100 16B 08455 16C 08456 0100 16D 07204 0100 DESCRIPTION QTY ITEM PARTNO DESCRIPTION QTY Crankcase 1 17 08442 Wrist Pin 3 Dipstick 1 19 08356 0010 Oil Seal 3 Crankcase
13. buyer or third party Normal wear and tear to standard wear parts Use of repair parts other than those manufactured or authorized by Giant Improper use of the product as a component part Changes or modifications made by the customer or third party The operation of pumps and or accessories exceeding the specifications set forth in the Operations Manuals provided by Giant Industries Inc DB Fab 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 RANTIES OR MERCHANTABILITY OR FITNESS FORA PARTICULAR PURPOSE AND ALL SUCH WARRANTIES ARE HEREBY DISCLAIMED AND EXCLUDED BY THE
14. eceestns 14 to 140 PSI 1 to 10 bar RPM EEn Up to 3450 RPM Plunger Diameter intactas T lZ saanson iaaieo 18mm Tl cnica ON EE 3 4mm Temperature of Pumped Fluids Up na 160 since 71 C Inlet Ports P230 3100 sivcavsscesendssevseeccesssacesbeavccessesaceaveavacevsriessivepecveesteensts 2 3 8 BSP Inlet Ports P23025 1OO reiasa ani a ae ati E 2 1 2 BSP Discharge Ports sneed ee EE EE 2 3 8 BSP Shaft ROADON eso iir setate eerie Eeu giele dee eeh ege ee Top of Pulley Towards Fluid End Crankshaft Diameter cicces cciiscssicestesscsseesicdestisccersteniceduistscesst eevcsvapebvossazcoste 24mm SAP dontisk Goan rendrnaen E 8mm KTR O eE Right Side Facing Manifold KEE 11 Ibs los wee 5 kg Crankcase Oil Capacity nee EE Aesar 0 2 liter Extended Crankcase Oil Capacity AE E 0 3 liter Volumetric Efficiency 1750 RPM vennen eneen 0 94 Volumetric Efficiency 3450 RPM nennen eneen 0 87 Mechanical Efficiency 3450 RPM eee 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 th
15. ect 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 2 3 4 5 6 7 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 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 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 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 val
16. etric Efficiency 3450 RPM nennen eneen 0 87 Mechanical Efficiency 3450 RPM neen evers 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 Tein oe ep e rating shown are the power REQUIREMENTS requirements for the pump Gas RPM GPM 1000 PSI 1500 PSI 2000 PSI 250 03 02 03 500 0 6 04 1000 1 2 450 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 engine power outputs must be approximately twice the pump nin power requirements shown above HP GPM X PSI 1450 Specifications Model P230 3100 5100 U S Metric 1750 RPM A vT Tandan aaas 1 1 GPM E 2000 PSI 4 2 LPM 137 bar 3450 RPM A inin i 2 05 GPM 2000 PSI 7 8 LPM 137 bar Inlet PresSUr cies csissncceestedetssceetesinceevsn
17. g 1 2 5100 pumps 1 Tension Screw 316 S S 3 37A 06272 Copper Washer 1 2 Crush Washer 316 S S 3 3100 pumps only 1 P200A 3100 5100 SERIES REPAIR KITS Plunger Packing Kit Valve Assembly Kit Oil Seal Kit Part 09602 Part 09211 Part 09144 Item Part Description Qty Item Part Description Qty Item Part Description Qty 23 08477 Grooved Seal 23A 08087 Grooved Seal Ring 23B 06163 Drip Shield 24 07904 Pressure Ring Position 16C 32 34 3 27 07849 0100 Valve Seat 6 19 08356 0010 Oil Seal 3 3 28 07491 0100 Valve Plate 6 3 29 07906 Valve Spring 6 3 30 07907 Valve Retainer 6 6 31 07853 0001 O Ring P200A 3100 5100 SERIES TORQUE SPECIFICATIONS Item Description Torque Amount ft Ibs 08456 0100 Tension Screw Plunger 220 in Ibs 07928 0100 Valve Plug 33 ft lbs 08316 0100 Hex Head Cap Screw Valve Casing 105 in Ibs 11 Z REPAIR INSTRUCTION P200A 3100 5100 SERIES 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 Apply one drop of Loctite 243 to the valve plugs 32 and tighten to 33 ft lbs 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 necessary Using a needle nose plie
18. is important to insure a positive head to the pump to prevent cavitation 3 The discharge plumbing from the pump should be properly sized to the flow rate to prevent line pressure loss to the work area It is essential to provide a safety bypass valve between the pump and the work area to protect the pump from pressure spikes in the event of a blockage or the use of a shut off gun 4 Use of a dampener is necessary to minimize pulsation at drive elements plumbing connec tions and other system areas The use of a dampener with Giant Industries Inc pumps is optional although recommended by Giant Industries Inc to further reduce system pulsa tion Dampeners can also reduce the severity of pressure spikes that occur in systems using a shut off gun A dampener must be positioned downstream from the unloader 5 Crankshaft rotation on Giant Industries Inc pumps should be made in the direction desig nated by the arrows on the pump crankcase Reverse rotation may be safely achieved by following a few guidelines available upon request from Giant Industries Inc Required horsepower for system operation can be ob tained from the charts on pages 3 9 6 Before beginning operation of your pumping system remember Check that the crankcase and seal areas have been properly lubricated per recommended schedules Do not run the pump dry for extended periods of time Cavitation will result in severe damage Always remember to check that
19. le size that corresponds with the pump GPM GPM X PSI zip 1450 P217A 3100 5100 PULLEY SELECTION amp HORSEPOWER REQUIREMENTS PUMP MOTOR PULLEY PULLEY npu apu 800 PSI 1200 PSI 1500 PSI 1700 PSI 2000 PSI Specifications Model P218A 3100 5100 U S Metric Ke te 3 4 GPM ooeec 12 5 LPM Discharge Pressure nennen erneer 2000 PSI sese 140 bar Inlet Pressure an aeerennenerenneneer ennen 90 PS naciona 6 2 bar RPM ON 1750 RPM Plunger Diameter ATO arden 18mm SMOKE asscssassacesei sisevsatensessiacsusiieesateviecaveisasiveel es LOA svcceeesiastvsiiecessetie 10 0mm Temperature of Pumped Fluids sss sese s 160 F eersten 71 C Inlet Ports P218A 3100 anne Inlet Ports P218A 5100 annen EEN 2 3 8 BSP REN 2 1 2 BSP Discharge Ports viii ninia iaa 2 3 8 BSP Shaft ROCAUOM sneverseranneer veseereerraarendeniastene Top of Pulley Towards Fluid End Crankshaft Diameter nennen OIA nn asnreensersennerdense 24mm Key Widths ieina OSI A 8mm Shaft LeS T Either Side WES H 11 lbs 110z 4 9 kg Crankcase Oil Capacity sese eee eee 8 1 TLOZ ssent 0 24 liters Volumetric Efficiency E 1750 RPM ereen 0 96 Mechanical Efficiency 1750 RPM enen 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 Pulley selection and pump speed are based on a 1725
20. roximately twice the pum pproximately twice the pump 500 07 05 07 09 power requirements shown above 1000 13 09 14 18 1450 We recommend a 1 15 service factor 1750 3000 electric motor as the power source To compute specific pump horse power requirements use the following formula be specified when selecting an Intermittent duty only HP GPM X PSI 1450 Specifications Model P227 3100 5100 U S Metric 1750 RPM RAUDES arcas Taisa aiia dE Eessen 2 1 GPM 2000 PSI 8 0 LPM 137 bar 3450 RPM A laaa ee dee 3 8 GPM 2000 PSI 14 4 LPM 137 bar Inlet PHESSUTEC corsa iia 4 35 to 140 PSI 0 3 to 10 bar RPM A EE execece Up to 3450 RPM Plunger Diameter A 18mm KST O acne 0 25 encierra 6 3mm Temperature of Pumped Fluids Up to 160 F 71 C Inlet Ports P227A 3100 inscricion 2 3 8 BSP Inlet Ports P227 A25 VOO caninas id 2 1 2 BSP Discharge POrts ainia aii 2 3 8 BSP Shatt ROTO iii diria Top of Pulley Towards Fluid End Crankshaft Diameter sisi irc ceca circa 24mm Key Width iii lada tii detinee 8mm Shaft Mounting isccricana scstveanacevsba cesevseveveesiacectes vecvssen ccotwea nates Right Side Facing Manifold Weib 1 onore O TE 11 Ibs los wee 5 kg Crankcase Oil Capacity neee TD ML OZ inn is 0 2 liter Extended Crankcase Oil Capacity DO TLZ ica aia 0 3 liter Volumetric Efficiency 1750 RPM nennen eneen 0 95 Volum
21. rs remove the inlet and discharge valve assemblies 27 30 and o ring 31 Inspect all parts for wear and replace as necessary Next use a 5mm allen wrench to remove the 8 socket head cap screws 34 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 12 By inserting a small screw driver between the valve seat 27 and the valve spring retainer 30 the valve assembly can be separated 6 Carefully slide the valve casing 26 out over the plungers 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 REPAIR INSTRUCTION P200A 3100 5100 SERIES Disassembly sequence of the back end of the P200A 3100 5100 series pump 1 2 3 4 5 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 If the bearings 12A and 12B and radial shaft seal 11 are still in the crankcase remove them Insp
22. uids Up to 160 F oenen 71 C Inlet Ports P217A 3100 ascii lacio aiii 2 3 8 BSP Inlet Fortes 2 1 2 BSP Discharge Por eiii 2 3 8 BSP Shatt te E Top of Pulley Towards Fluid End Crankshaft Diameter US rita 24mm Key tele EE OI RE 8mm Shatt le E Either Side K En NR ln GE sasaran 4 9 kg Crankcase Oil Capacity ce eee eee R 0 24 liters Volumetric Efficiency E 1750 RPM annen eeneerneeeneen 0 90 Mechanical Efficiency 1750 RPM agingga toein 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 We recommend that a 1 1 service factor be specified 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 2 The desired pressure is achieved by selecting the use the following formula correct nozz
23. ve 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 Replace the six o rings 31 and the six valve assemblies 27 30 Now replace the six valve plugs with o rings 32 and 33 and tighten securely with a 22mm socket wrench to 33 foot pounds Se Fill crankcase with 8 1 ounces of oil Pump Mounting Selection Guide Bushings 07174 24 mm Tapered H Bushing Pulley amp 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 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 Fouled discharge valve Fouled inlet strainer Worn or Damaged hose Worn or Plugged relief valve on pump Cavitation pump for restrictions Replace nozzle Clean valve assembly Clean strainer Repair Replace hose Clean Reset and Replace worn parts Check suction lines on inlet of 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 cr
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