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-service 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 dateof shipment for
all pumps used in NON-SALINE, 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 negligence or fault of the buyer or third party.
2. Normal wear and tear to standard wear parts.
3. Use of repair parts other than those manufactured or authorized by Giant.
4. Improper use of the product as a component part.
5. Changes or modifications made by the customer or third party.
6. The operation of pumps and or accessories exceeding the specifications set forth in the Operations
Manuals provided by Giant Industries, Inc.
Liability under this warranty is on all non-wear parts and limited to the replacement or repair of those products
returned freight prepaid to Giant Industries which are deemed to be defective due to workmanship or failure of
material. A Returned Goods Authorization (R.G.A.) number and completed warranty evaluation form is required
to the return to Giant Industries of all products under warranty consideration. Call (419)-531-4600 or fax (419)-5316836 to obtain an R.G.A. number.
prior
MODEL
GP8155-R
WITH INTEGRAL GEARBOX 180o REVERSE
Triplex Ceramic
Plunger Pump
Model Manual
Repair or replacement of defective products as provided is the sole and exclusive remedy provided hereunder and
the MANUFACTURER SHALL NOT BE LIABLE FOR FURTHER LOSS, DAMAGES, OR EXPENSES, INCLUDING
INCIDENTAL AND CONSEQUENTIAL DAMAGES DIRECTLY OR INDIRECTLY ARISING FROM THE SALE OR USE
OF THIS PRODUCT.
THE LIMITED WARRANTY SET FORTH HEREIN IS IN LIEU OF ALL OTHER WARRANTIES OR REPRESENTATION,
EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION ANY WARRANTIES OR MERCHANTABILITY OR
FITNESS FOR A PARTICULAR PURPOSE AND ALL SUCH WARRANTIES ARE HEREBY DISCLAIMED AND
EXCLUDED BY THE MANUFACTURER.
Installation of the Giant Industries, Inc., pump is not a
complicated procedure, but there are some basic steps
common to all pumps. The following information is to be
considered as a general outline for installation. If you
have unique requirements, please contact Giant Industries, Inc. or your local distributor for assistance.
1. The pump should be installed flat on a base to a
maximum of a 15 degree angle of inclination to ensure
optimum lubrication.
2. The inlet to the pump should be sized for the flow rate
of the pump with no unnecessary restrictions that can
cause cavitation. Teflon tape should be used to seal all
joints. If these pumps are to be operated at temperatures
in excess of 86
to the pump to prevent cavitation.
3. The discharge plumbing from the pump should be
properly sized to the flow rate to prevent line pressure
loss to the work area. It is essential to provide a safety
bypass valve between the pump and the work area to
protect the pump from pressure spikes in the event of a
blockage or the use of a shut-off gun.
o
F, it is important to insure a positive head
GP8155-R -- DIMENSIONS - (mm)
5. Crankshaft rotation on Giant Industries, Inc.
pumps should be made in the direction designated by
the arrows on the pump crankcase. Reverse rotation
may be safely achieved by following a few guidelines
available upon request from Giant Industries, Inc.
Required horsepower for system operation can be
obtained from the charts on page 3.
6. Before beginning operation of your pumping
system, remember: Check that the crankcase and seal
areas have been properly lubricated per recommended schedules. Do not run the pump dry for
extended periods of time. Cavitation will result in
severe damage. Always remember to check that all
plumbing valves are open and that pumped media
can flow freely to the inlet of the pump.
The service life of the seals is
maximized if a minimal amount of leakage is
present. A few drops of water can drip from
each plunger every minute. Leakage has to be
examined every day; the plunger seals must be
changed should leakage become excessive
(=constant dripping).
4. Use of a dampener is necessary to minimize pulsation
at drive elements, plumbing, connections, and other
system areas. The use of a dampener with Giant Industries, Inc. pumps is optional, although recommended by
Giant Industries, Inc. to further reduce system pulsation.
Dampeners can also reduce the severity of pressure
spikes that occur in systems using a shut-off gun. A
dampener must be positioned downstream from the
unloader.
IMPORTANT OPERATING CONDITIONS
Failure to comply with any of these conditions invalidates the warranty
1. Prior to initial operation, add oil to crankcase so that
oil level is between the two lines on the oil dipstick. DO
NOT OVERFILL.
Use Industrial synthetic gear lube oil (ISO VG 220),
such as Mobil Gear 630, Shell Omala oil 220 or
Texaco Meropa 220.
Crankcase oil should be changed after the first 50 hours
of operation, then at regular intervals of 200 hours or
less depending on operating conditions.
Run pump for one (1) min at ZERO PSI before operating
under pressure.
2. Pump operation must not exceed rated pressure,
volume, or RPM. A pressure relief device must be
installed in the discharge of the system.
3. Acids, alkalines, or abrasive fluids cannot be pumped
unless approval in writing is obtained before operation
from Giant Industries, Inc. Pump fluid should be filtered
to 300 micron.
Finally, remember that high pressure operation in a
pump system has many advantages. But, if it is
used carelessly and without regard to its potential
hazard, it can cause serious injury.
4. Run the pump dry approximately 10 seconds to
drain the water before exposure to freezing temperatures.
5. The pump and cooling system must
be emptied if there is a danger of frost. Note that
travel wind, for example, can cause water in pumps
fitted on open vehicles to freeze even if the outside
temperature is above freezing point.
6. Inlet pressure not to exceed 29 PSI when using the
integrated oil cooling system. If using a separate
cooling system (max. 29 PSI), the inlet pressure can
be a maximum of 145 PSI.
To empty the cooling circuit, remove the L-joints
(K11) on the pump head (50). Blow out the circuit
liquid at the joint connection (K11/K7) using
compressed air.
The torque tension on the valve casing nuts (49A)
should be checked after approximately 200 operating
hours. Please see page 7 for torque values.
2
11
GP8155-R PUMP REPAIR INSTRUCTIONS
15) Replace seal retainer (33), seal (32) and clip ring (33B). Seal (32) must always be installed
so the seal lip on the inside diameter faces the oil. Possible axial float of the seal retainer (33)
to be compensated with shims (33C). Re-assemble the seal sleeves (39) and plunger pipes
(36B). Tighten the tension screw (36C) to 30 Ft-lbs. Replace valve casing and tighten hexagon
16) Mount cooling plate (K1) and gear cover (K3) with their respective seals (K2). When assembling
the cooling circuit line, make sure that the oil cooler connection (K7) is always joined to the
upper connection (K3) of the gear cover.
Heat ball bearings (74 and 75) first before pressing them on to the pinion. Press the cogwheel
slightly on to the crankshaft so that the pinion (69) together with the ebaring (74) can be inserted.
Move the pinion (69) against the cogwheel and make them mate perfectly when mounting. Then
carefully tap the cogwheel and the pinion simultaneously on to the crankshaft and into the bearing
seat. Fit fitting disc (69) and secure screw (72) with Loctite. Fit the seal (76) on to the cylindrical
pins (68).
Push the gear cover (66) carefully onto the bearing (75). Make sure that the radial shaft seal (73)
does not get damaged during fitting onto the pinion.
Before putting into operation again, turn the reduction gear shaft by hand at least
four full turns to make sure the gear is correctly aligned.
Specifications
Model GP8155-R
U.S.(Metric)
Volume .............................................................Up to 74.8 GPM...... (283 LPM)
Discharge Pressure .........................................Up to 2900 PSI ........ (200 bar)
Speed ...............................................................Up to 580 RPM ....... 580 RPM
Inlet Pressure...................................................Up to 29 PSI............ (2.0 bar)
The theoretical gallons per revolution (gal/rev) is 0.129.
T o find specific outputs at various RPM, use the formula:
GPM = 0.129 x RPM
HORSEPOWER RATINGS:
The rating shown are the power
requirements for the pump. Gas
engine power outputs must be
approximately twice the pump
power requirements shown above.
We recommend a 1.15 service
factor be specified when selecting
an electric motor as the power
source. To compute specific pump
horsepower requirements, use the
following formula:
GPM X PSI
1450
= HP
10
3
EXPLODED VIEW - GP8155-R
GP8155-R PUMP REPAIR INSTRUCTIONS
To Dismantle Crankcase Gear
11) T ake out plungers and seal sleeves as described
above. Drain the oil by taking off the plug (12). After
removing the clip ring (33B), lever out the seal retainer
(33) and seal (32) with a screwdriver. Open hose
adapter (K11) and remove gear cover (K3) by removing
the socket head cap screws (K5). Remove the cooling
vane plate (K1) by removing the screws (K4)
13) Push connecting rod halves together with the
crosshead as far as possible into the crosshead
guide. Remove bearing cover (14). Begin dismantling
of the reduction gear by removing screws (67). Press
off gear cover (66) by screwing two screws into both
threaded bores. Remove screw (72) and take off fitting
disc (69). Remove cogwheel from shaft with a removal
tool and take the crankshaft out of the crankcase by
gently tapping it with a rubber mallet. Remove connecting rod (24) and crosshead (25) from crankcase.
Remember that this assembly must be re-assembled
exactly as it was removed. Check surfaces on connecting rods (24), crankshaft (22) and crosshead (25).
Check the surfaces of the crosshead guides in the
crankcase for any uneveness.
12) Remove the connecting rod screws (24).
Connecting rods are marked 1 to 3
for identification. Do not rotate connecting rod
halves or interchange them. When re-assembling,
the connecting rod must be fitted in their exact
original position on the crankshaft journals.
14) Reassemble in reverse order. Replace the
connecting rod and crosshead exactly as they
were removed. Press the bearing ring (21) past
the clip ring groove. Replace the shims (21C).
Snap in the clip ring (19) and insert crankshaft
from other side, then press in the roller bearing
(20). Mount bearing cover (14) and tighten screws
(17) to 64 Ft-lbs. Adjust axial play (clearance) on
the crankshaft to minimum 0.1mm / 0.15mm
using shims (21A/B). Connecting rods must sit
exactly in the middle of the crankshaft journal.
Mount connecting rod halves in the exact, original
position and tighten to 37 Ft-lbs. The shaft should
turn easily .
Connecting rods must be able to
move slightly sideways on the stroke journals.
4
9
GP8155-R PUMP REPAIR INSTRUCTIONS
Parts List - GP8155-R
7) Be careful not to damage the seal
sleeve (39) and pressure ring (41). Check the inner
diameter of the pressure ring for wear and if necessary replace together with seals (40) and (42). Clean
all parts. New parts should be lightly coated with
silicon grease before installation. Insert the seal unit
(40, 41, 42 43) into the sleeve. Push the ceramic
plunger carefully through the seals from the crankcase side. If necessary, the seals can be held tightly
using a suitable pipe support held on the other side of
the seal sleeve.
9) Coat the seal sleeve(39) lightly with anti-corrosive
grease (e.g. molycote no.Cu-7439) in its fitted area
towards the crankcase. Insert the seal sleeves in to
their crankcase fittings. Coat the threads of the
tension screw (36C) lightly with thread glue and
insert it together with a new copper ring (36D)
through the ceramic pipe. Turn the pump by hand
until the plunger (25) rests against the plunger pipe.
Tighten the tension screw at 30 Ft-lbs.
Thread glue must never come between
the plunger pipe (36B) and centering sleeve (36E).
Overtensioning of the plunger pipe by excessive
tightening of the tension screw and/or dirt or damage
on the mounting surfaces can lead to plunger pipe
breakage. Insert the seal tension spring (45) and oring (39A) in to the seal sleeve (39).
8) Take out the seal case (38) from the valve casing
(50) and check o-rings (38A) (if necessary secure
two screwdrivers in the front o-ring groove to extract
seal casing from valve casing). Coat seals with
silicon grease before installing.
Mounting surfaces of the crankcase
and the valve casing must be clean and free of
damage. The components must lie exactly and
evenly on one another. The same exactness applies
for all centering positions in the crankcase, pressure and valve casing.
Replacing Valve Casing:
10) Put seal cases (38) in the centering holes of the
valve casing, then push valve casing carefully on to
centering studs (50A). Tighten hexagon screws (49A)
evenly and crosswise at 266 Ft.-lbs.
The torque tension on the screws (49A)
must be checked after 8-10 operating hours; the pump
must be at zero pressure. Thereafter , the tension is
to be checked every 200 operating hours.
resistance in inlet line, clean inlet
filter, lower water temperature.
Irregular pressureWorn V alvesExamine valves
O-ring on valves or inlet valve
adapter leaksExamine O-rings, check valve
casing for unevenness on the
sealing surfaces
Oil leaks at visible part of plunger Gear sealing is leakingExamine seals and running surface
of plunger
Dirty, milk-colored or frothy oilWater has mixed with oilReplace oil immediately, find & fix
the cause
Oil leakage on the crankshaftShaft seal ring leaksCheck seal and shaft
Noise increases without the lossWorn bearingDismantle gear, examine all part s,
replace worn parts, check oil level. If
service life was too short, check for
excess strain or whether lubrication
intervals were too long. Only
specified lubricants are to be used.
1) Remove socket head cap
screws (58)
4) Remove valve assembly (52) from discharge valve adapter (56) by gently twisting apart. The spring tension
cap (51A, 52A) is screwed together with the valve seat (51B or 52B). Screw off spring tension cap. Takeout
springs (51E, 52E) and valve plate (51C, 52C). Check sealing surfaces and O-rings (51D, 52D). Replace worn
parts. Coat threads of valve seat with silicon grease or molycote anti-seize Cu-7439 when reassembling.
Before refitting the valves, clean the sealing surfaces in the casing and check for any damage. Coat o-rings
(51D, 52D & 56A) with silicone grease to help with re-assembly . Replace valve assembly (51) and pressure
spring (57). Assemble valve assembly (52) to discharge valve adapter (56) by t apping together lightly with
rubber mallet. While replacing the valve assemblies use a rubber mallet to tap the top of the valve puller lightly .
This insures proper seating. Replace pressure spring (57A) and the discharge casing (50B). Tighten caps (58)
at 133 Ft-lbs; check torque tension after 8-10 operating hours.
2) Lift discharge casing
(50B) up and away .
3) Take out pressure springs
(57A). Pull out assembled
valves (51 & 52) with valve puller.
To Check Seals and Plunger Pipe
5) Remove hexagon nuts (49A) and valve
casing together with seal case (38) from
crankcase (1). If necessary, carefully t ap the
valve casing (50) past the centering stud (50A)
using a rubber hammer.
IMPORTANT! If necessary, support the valve
casing by resting it on wooden blocks or by
using a pulley.
6) Remove tension screw (36C) and take
seal sleeve (39) together with all mounted
parts out of the drive. Pull plunger pipe (36B)
out of the seal assembly and check for any
damage. Carefully , remove seal rings (40) and
sleeves (42) with a screwdriver.
7
6
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