Assessments - 2, GPA: 4.5
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DESCRIPTION QTY. 1 08300 Crankcase 1 2 08301 Dipstick and Gasket, Black 1 3 08302 Crankcase Cover, Short 1 3 08302-L Crancase Cover, Long 1 3A 07190 Drain Plug 1 3B 13262 Gasket for drain plug 1 4 08005 O-Ring 1 5 06273 Oil Drain Plug with Gasket 1 5A 08192 Gasket 1 6 07188 Screw, Short Cover 4 6A 01176-2 Spring Washer 4 7 08303 Bearing Cover I 2 8 08490 Sight Glass 1 9 08492 O-Ring 1 10 07225 Screw with Lock Washer 11 01166 Radial Shaft Seal 1 12A 08020 Ball Bearing 1 12B 01020 Ball Bearing 1 13 06694 Crankshaft (P205) 1 13 08465 Crankshaft (P206) 1 13 12258 Crankshaft (P208) 1 14 06207 Woodruf Key 1 15 08333 Connecting Rod 3 ITEM PART NO. DESCRIPTION QTY. 16 06641 Plunger, Complete, 12mm 3 17 08442 Wrist Pin 3 19 08356-0010 Oil Seal 3 20 06645 Seal Case 3 21 08443 O-Ring 3 23 07391 V-Sleeve 3 23A 08598 V-Sleeve, Weep 3 24 07392 Support Ring 3 25 06646 Weep Return Ring 3 26 06647 Valve Casing 1 27 07849 Valve Seat 6 28 07491 Valve Plate 6 29 07906 Valve Spring 6 30 07907 Valve Spring Retainer 6 31 07853 O-Ring 6 32 07928 Valve Plug 6 32X 07946 Valve Assemblv Complete 6 33 07913 O-Ring 6 34 08316 Hex Head Cap Screw 8 38 13338 Plug, 3/8" BSP 1 38A 07661 Seal 1 39 07109 Plug, 1/2" BSP 1 39A 08486 Copper Seal Ring 1 P205/206/208 REPAIR KITS Plunger Packing Kit Part # 09527 Item # Part # Description Otv. 23 07391 V-Sleeve, weep 3 23A 08598 V-Sleeve 3 24 07392 Support Ring 3 Oil Seal Kit Part # 09144 Item # Part # 19 08356-0010 Description Oil Seal Oty. 3 Valve Assembly Kit Part # 09116 Item # Part. # Description Otv. 32X 07946 Valve Assembly Complete 6 31 07853 O-Ring 6 P205/206/208 TORQUE SPECIFICATIONS Position Item# Description Torque Amount 32 07928 Valve Plug 33 or 59* (ft.-lbs.) 34 08316 Hex Head Cap Screw, Valve Casing 105 (in.-lbs.) 7 REPAIR INSTRUCTIONS - P205/206/208 PUMPS NOTE: Always take time to lubricate all metal and nonmetal parts with a light film of oil before reassembly. This step will ensure proper fit, at the same time protecting the pump nonmetal parts (i.e., the elastomers) from cutting and scoring. 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 damaged. 2. Using a needle nose pliers, remove the inlet and discharge valve assemblies (32X). 3. By inserting a small screw driver between the valve seat (27) and the valve spring retainer (30), the valve assembly can be separated. 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. 5. Next, use a 5mm alien wrench to remove the 8 socket head cap screws (34). 6. 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! 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 crankshaft (13), connecting rod (15), and plunger assembly (16) ffom the gear end. Then the oil seals can be pushed out from the rear. Please contact Giant for details. REPAIR INSTRUCTIONS - P205/206/208 PUMPS 10. If the ceramic plunger pipe (16B) is damaged, replace entire plunger assembly by removing crankshaft (13). Contact Giant for further details. NOTE: If there are deposits of any kind (Le., lime deposits) in the valve casing, be certain that the weep holes in the weep return ring (2S) and valve casing (26) have not been plugged. Reassembly sequence of the P205/206/208 PUMPS 1) If oil seals (19) were removed, replace with seal lip towards crankcase. Lubricate seals before replacing. Contact Giant for assistance with the reassembly of the gear end. 2) Replace seal case (20) with o-rings (21) over plungers. Generously lubricate o-rings and oil seal before reassembly. Replace weep v-sleeve (23A) over plungers (16).. 3) Generously lubricate v-sleeve (23). Assemble v-sleeves (23) 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). 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: 419/531-460...
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