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Remove the v-sleeve (23) from the seal case (20). 5. Next, use a 5mm allen wrench to remove the 8 socket head cap screws (34). Inspect all parts, including o-ring (21) for wear and replace as necessary Check surfaces of plunger (16). A damaged surface will cause accelerated wear on the seals. Deposits of any kind must be carefully removed from the plunger surface. A damaged plunger must be replaced! 6. Carefully slide the valve casing (26) out over the plungers. 12 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. REPAIR INSTRUCTIONS - P200A SERIES 9. If the ceramic plunger pipe (16B) is damaged, remove the plunger bolt (16C). Discard the old plunger pipe (16B) and copper gasket (16D), and clean the old locktite from the plunger bolt (16C) and plunger base (16A). Replace the plunger with the new one and locktite the plunger bolt and torque to 120 inch-pounds. NOTE: If there are deposits of any kind (i.e., lime deposits) in the valve casing, be certain that the weep holes in the weep return ring (25) and valve casing (26) have not been plugged. Reassembly sequence of the P200A series pump 1) If oil seals (19) were removed, replace with seal lip towards crankcase. Lubricate seals before replacing. 2) 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).. 3) 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. 4) Replace the six o-rings (31) and the six valve assemblies (32X). Now replace the six valve plug o-rings ( 33). 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. For maintenance of the gear end of your pump contact Giant Industries or your local distributor. Phone: 419/531-4600 NOTE: Contact Giant Industries for Service School Information. Phone: (419)-531-4600 13 PUMP SYSTEM MALFUNCTION MALFUNCTION The Pressure and/or the Delivery Drops CAUSE Worn packing seals Broken valve spring Belt slippage Worn or Damaged nozzle Fouled discharge valve Fouled inlet strainer Worn or Damaged hose Worn or Plugged reliefvalve on pump Cavitation Unloader REMEDY Replace packing seals Replace spring Tighten or Replace belt Replace nozzle Clean valve assembly Clean strainer Repair/Replace hose Clean, Reset, and Replace worn parts Check suction lines on inlet of pump for restrictions Check for proper operation Water in crankcase High humidity Reduce oil change interval Worn seals Replace seals Noisy Operation Worn bearings Replace bearings, Refill crankcase oil with recommended lubricant Cavitation Check inlet lines for restrictions and/or proper sizing Rough/Pulsating Worn packing Replace packing Operation with Inlet restriction Check system for stoppage, air Pressure Drop leaks, correctly sized inlet plumbing to pump Accumulator pressure Recharge/Replace accumulator Unloader Check for proper operation Cavitation Check inlet lines for restrictions and/or proper size Pressure Drop at Restricted discharge plumbing Re-size discharge plumbing to Gun flow rate ofpump Excessive Leakage Worn plungers Replace plungers 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 14 P200A DIMENSIONS (inches) 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 self-serve 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 NONSALINE, 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 negligenc...

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