Giant P200A-3100 Series Repair and Setup guide

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REPAIR INSTRUCTIONS - P200A-3100 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.
2. Using a needle nose pliers,
remove the inlet and dis-
charge valve assemblies
(27-30), and o-ring (31).
Inspect all parts for wear and
replace as necessary.
3. By inserting a small screw
driver between the valve
seat (27) and the valve
spring retainer (30), the
valve assembly can be sepa-
rated.
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, in-
cluding o-ring (21) for wear
and replace as necessary.
8.Check surfaces of plunger pipe
(16B). A damaged surface will cause
accelerated wear on the seals. De-
posits of any kind must be carefully
removed from the plunger surface. A
damaged plunger must be replaced!
When replacing the crush washer
(item 16D), make sure the rolled side
of the crush washer is placed on the
ceramic. Prior to installation, care-
fully crush the seal ring on a hand
press.
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.
4. Apply one drop of Loctite
243 to the valve plugs (32)
and tighten to 55 ft.-lbs.
(75 Nm).
5. Next, use a 5mm allen
wrench to remove the 8
socket head cap screws
(34).
6. Carefully slide the valve
casing (26) out over the
plungers.

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Disassembly sequence of the back end of the P200A-3100 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 con-
necting 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 assembly (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 (16C). Replace crush washer (16D). NOTE: Carefully flatten crush washer before replacing it.
Inspect all parts and replace as necessary.
Reassembly sequence of the P200A-3100 series pump
1) Reassemble plunger assembly (16) (apply a drop of Loctite to the tension screw (16C) threads) and the
connecting rod (15) with wrist pin (17). Place assemblies in crankcase (1). Install crankshaft through con-
necting 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 drip shield (23B) and v-sleeve (23A) over plungers (16)..
5) Generously lubricate v-sleeve (23) and assemble 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 106 inch-pounds (12 Nm) in a crossing pattern (see be-
low).
6) Re-install 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 55 foot-pounds (75 Nm).
7) Fill crankcase with 7.5 ounces (0.2 L) of oil.
REPAIR INSTRUCTIONS - P200A-3100 SERIES
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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Pump Mounting Selection Guide