Giant installation instructions Repair Instructions P205/P206/P207/P208/P209/P210/P211 Pumps

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.

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.

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.

2.Using a needle nose pliers, remove the inlet and discharge valve assemblies (32X).

5.Next, use a 5mm allen wrench to remove the 8 socket head cap screws (34).

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!

3.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.

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.