Repair Instruction P200A-3100/5100 Series | Giant P227-5100 specification

REPAIR INSTRUCTION - P200A-3100/5100 SERIES

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.Apply one drop of Loctite 243 to the valve plugs (32) and tighten to 33 ft.-lbs.

2.Using a needle nose pliers, remove the inlet and discharge valve assemblies (27-30) and o-ring (31). Inspect all parts for wear and replace as necessary.

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

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.

7.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

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.