REPAIR INSTRUCTION - P200A-3100/5100 SERIES

Disassembly sequence of the back end of the P200A-3100/5100 series pump.

1)Before you begin, drain the oil from the crankcase.

2)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.

3)If the bearings (12A and 12B) and radial shaft seal (11) are still in the crankcase, remove them. Inspect both bearings and seal for wear and replace if necessary.

4)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.

5)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)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.

2)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).

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

4)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)..

5)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 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 (see below).

6)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.

7)Fill crankcase with 8.1 ounces of oil.

5

3

2

7

8

1

4

6

Pump Mounting Selection Guide

Bushings

07174 - 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-1.0”XH=1.812”) 01161 - Plated Steel Channel Rails (L=5.75”x W-1.0”XH=2.50”)

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Giant P220-5100, P219-3100, P218-5100, P217-3100, P217-5100, P218-3100, P219-5100, P221-3100 Pump Mounting Selection Guide
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P220-3100, P227-5100, P218-3100, P227-3100, P220-5100 specifications

Giant has established itself as a leader in the cycling industry, known for its innovative designs and advanced technologies. Among its impressive lineup of bicycles, the P221-3100, P217-3100, P230-5100, P219-3100, and P230-3100 models stand out for their unique features and performance capabilities.

The Giant P221-3100 is renowned for its lightweight aluminum frame, which strikes a perfect balance between strength and agility. The bike features a Shimano drivetrain that ensures smooth and reliable shifting under various conditions. Its geometry is designed for enhanced stability, making it an ideal choice for both casual riders and competitive cyclists. The inclusion of hydraulic disc brakes provides superior stopping power, especially in wet or downhill conditions.

Similarly, the P217-3100 showcases a blend of comfort and performance. It is equipped with a plush saddle and ergonomic handlebars that promote a more relaxed riding posture. The bike's 27.5-inch wheels offer a perfect compromise between speed and control, making it versatile enough for urban commuting and off-road exploration. The P217-3100 also integrates Giant’s proprietary technology, which enhances energy efficiency to give riders a significant boost during climbs.

The P230-5100 takes performance to a higher level with its advanced suspension system. This model features a full-suspension design that absorbs shocks effectively, ensuring a smooth ride on rugged terrains. With a robust frame and components designed for durability, the P230-5100 is perfect for aggressive trail riding. Additionally, its tubeless-ready tires provide excellent traction and reduce the risk of flats, giving riders peace of mind on longer rides.

The P219-3100, on the other hand, is designed for speed enthusiasts. This road bike is characterized by its aerodynamic frame and lightweight construction, allowing riders to achieve impressive speeds on flat surfaces. The bike's cutting-edge gearing system ensures optimal power transfer, making it a favorite among competitive cyclists. Integrated LED lights also enhance safety during nighttime rides.

Lastly, the P230-3100 combines the best of both worlds—speed and versatility. With a minimalist design and a strong emphasis on aerodynamics, this bike is perfect for both racing and recreational riding. Its advanced braking technology enhances control, while the strategically designed frame geometry caters to various riding styles.

In conclusion, the Giant P221-3100, P217-3100, P230-5100, P219-3100, and P230-3100 models encapsulate Giant's commitment to quality and performance. Each bike caters to different riding preferences while maintaining the brand's hallmark features of durability, comfort, and innovation. Whether for thrill-seeking on rugged trails or smooth rides on city streets, these bicycles are sure to impress riders of all levels.
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