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REPAIR INSTRUCTION - P200A-3100/5100 SERIES
Disassembly sequence of fluid end of P200A-3100/5100 series pump
Note: Always take time to lubricate all metal and nonmetal parts with a light film of oil before reassem-
bly. 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). By inserting a
small screw driver between the valve seat (27) and the valve spring retainer (30), the valve assembly
can be separated. Remove the o-ring (31). Inspect all parts for wear and replace as necessary.
3) Next, use a 5mm allen wrench to remove the 8 socket head cap screws (34). Carefully slide the valve
casing (26) out over the plungers. Remove the weep return ring (25), pressure ring (24), and v-sleeve
(23) from the valve casing (26). Remove the v-sleeve (23) from the seal case (20). Inspect all parts,
including o-ring (21) for wear and replace as necessary.
4) 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 re-
placed!
5) 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.
5) 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. If the oil seals are not to be replaced,
proceed to the back end disassembly sequence and carefully pry the seals loose after the plungers have
been removed from the crankcase. The seals should not be reinstalled until after step #2 of the "Reas-
sembly Sequence".