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-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.
GIANT INDUSTRIES, INC.
900 N. Westwood Ave.
Toledo, Ohio 43607
(419) 531-4600
FAX (419) 531-6836
www.giantpumps.com
Copyright 2008 Giant Industries, Inc.
Contents:
Installation Instructions: page 2
Pump Specifications: page 3
Exploded View/Parts List: pages 4-5
Repair Kits/Tool List:/Torque Specifications page 6
Troubleshooting Chart: page 6
Repair Instructions: pages 7-10
Dimensions: page 11
Updated 4/084/08 GP8155-R.PMD
Warranty Information back page
INSTALLA TION INSTRUCTIONS
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)
Plunger Diameter............................................. 2.17” ........................ 55mm
Plunger Stroke .................................................2.83”........................ 72mm
Crankshaft Diameter .......................................2.76”........................ 70mm
Key Width........................................................0.55” ........................ 14mm
Crankshaft Mounting ......................................................................... Either side
Shaft Rotation .................................................................................... Top of pulley
........................................................................................................... Towards manifold
T emperature of Pumped Fluids........................Up to 86 oF .............. (30 oC)
Inlet Ports .......................................................................................... (2) 3" BSP
Discharge Ports ................................................................................. (2) 1-1/4" BSP
Weight ..............................................................794 lbs. .................... (360kg)
Crankcase Oil Capacity...................................3.7 Gal. .................... (14.0 liters)
Fluid End Material............................................Nickle plated Spheroidical Cast Iron
Consult the factory for special requirements that must be met if the pump is to
operate beyond one or more of the limits specified above.
GP8155-R HO RSEPO WER
REQUIREMENTS
RPM GPM 500 PSI 1000 PSI 200 0 PSI 3 000 PSI
300 38.7 13.3 26.7 53.4 80.1
400 51.6 17.8 35.6 71.2 106.8
500 64.5 22.2 44.5 89.0 133.4
580 74.8 25.8 51.6 103.2 154.8
SPECIAL NOTE:
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.
8
Item Part Description Qty
1 05410 Crankcase 1
2 06893 Oil Filler Plug Assy with Vent 1
3 05411 Rear Foot for Crankcase 2
4 05412 Front Foot for Crankcase 2
5 05413 Hexagon Socket Screw 4
6 05414 Hexagon Socket Screw 4
7 05381 Plug 3/8 for Oil Dipstick 1
8 05035 Oil Dipstick Assy 1
9 01009 O-Ring 1
10 05415 Plug M33*1.5 1
11 07102 O-Ring 1
12 06273 Plug G3/8 3
13 22929 Copper Washer 4
14 05036 Bearing Cover Closed 1
16 05037 O-Ring 1
17 05038 Hexagon Socket Screw M12 8
18 05039 Spring Ring 8
19 05124 Clip Ring 1
20 05416 Tapered Roller Bearing 1
21 05417 Tapered Roller Bearing 1
21A 05042 Fitting Disc 3
21B 05043 Fitting Disc 3
21C 05113 Fitting Disc 3
22 05418 Crankshaft For Turned Gear 1
23 05419 Fitting Key 1
24 05047 Conn-rod Assy 3
25 05048 Crosshead c/w Plunger 3
28 05049 Crosshead Pin 3
29 05051 Hexagon Screw 6
29A 07408 Hexagon Nut 2
29B 05420 Bracket 2 for Cooling Hose 2
29C 05421 Support Clamp 2
29D 05422 Bracket 1 for Cooling Hose 1
30 05052 Cover Plate 1
30A 07225-0100 Hexagon Screw 5
30B 13136 Grommet 5
30C 08280 Washer 9
30D 05050 Splash Cover 1
31 07623 Eye Bolt 4
32 05058 Radial Shaft Seal 3
33 05055 Seal Retainer 3
33A 05056 O-Ring 3
33B 05054 Clip Ring 3
33C 05059 Fitting Disc 3
34 05060 Oil Shield 3
36B 05280 Plunger Pipe 3
36C 05062 Tension Screw 3
36D 07665 Copper Washer 3
36E 06900 Centering Sleeve 3
38 05283 Seal Case 3
38A 13286 O-Ring 6
38B 05281 Support Ring 6
39 05275 Seal Sleeve 3
39A 05066 O-Ring 3
40 07723 Compact Ring 3
41 05276 Pressure Ring 3
42 05277 Sleeve 9
43 05278 Sleeve Support Ring 3
45 05279 Seal T ension Spring 3
49 05072 Stud Bolt 8
49A 05073 Hexagon Nut 8
50 05074 V alve Casing 1
Item Part Description Qty
50A 13162 Centering Stud 2
50B 05075 Discharge Casing 1
51 05076 Suction Valve Assy. 3
51A 05077 Spring Tension Cap 3
51B 05078 Suction Valve Seat 3
51C 05079 Valve Plate 3
51D 07658 O-Ring 3
51E 05080 V alve Spring 3
51F 05081 Valve Spring Guide 3
52 05082 Discharge Valve Assy 3
52A 05077 Spring Tension Cap 3
52B 05084 Discharge V alve Seat 3
52C 05079 Valve Plate 3
52D 06258 O-Ring 6
52E 05080 V alve Spring 3
52F 05081 Valve Spring Guide 3
56 05085 Discharge V alve Adaptor 3
56A 06258 O-Ring 3
57 05086 Pressure Spring 3
57A 07210-0100 Pressure Spring 3
58 05087 Hexagon Socket Screw 12
59 07109 Plug G1/2 2
59A 06272 Copper Seal 2
60 06909 Plug G1 1/4 1
61 05088 Plug G3 1
62 05302 Plug G1/4 6
62A 06934 Copper Gasket 6
66 05423 Gear Cover 1
67 05424 Hexagon Screw 10
67A 07274 W asher 10
68 05425 Cylinder Pin 4
69 05426 Gear Wheel Set
70 07614 Fitting Key 1
72 05427 Hexagon Screw 1
73 05428 Shaft Seal Ring for Gear 1
74 05429 Roller Bearing 1
75 05430 Roller Bearing 1
75A 05431 Fitting Disc 1
76 05432 Gear Seal 2
77 05433 Flange c/w Gear 1
78 05025 Oil Cooler 1
79 07662 Mounting Aid for Valve 1
80 07544 Hexagon Socket Screw M8 1
81 05434 Hexagon Socket Screw 9
K1 05026 Cooling Vane Plate 1
K2 05027 Seal for Gear Cover 2
K3 05028 Gear Cover 1
K4 05029 Hexagon Hd Cntrsnk Screw 8
K5 07381 Hexagon Socket Screw 8
K6 08041 Washer 8
K7 05030 Connection for Oil Cooler 1
K8 06272 Copper Seal 6
K9 07109 Plug G1/2 2
K10 05120 Connecting Branch 3
K11 05032 U-Joint Connector c/w Nut 3
K12 05033 Tube for Cooler 2
K13 05402 Hose Clamp 4
K14 05435 Hose Guard 2
K15 05404 Hose Coupling Nut 1
K16 05436 Flat Gasket 4
(2200 RPM=3.8) 1
5
GP8155-R PUMP REPAIR KITS
Plunger Packing Kit #09616
Item Part # Description Qty .
38A 13286 O-Ring 6
39A 05066 O-Ring 6
40 07723 Seal Ring 3
42 05277 V -Sleeve 9
GP8155-R PUMP REPAIR INSTRUCTIONS
Valve Inspection and Repair
Inlet Valve Kit - #09587
Item Part # Description Qty .
51B 05078 Inlet V alve Seat 1
51C 05079 V alve Plate 1
51D 07658 O-Ring 1
51E 05080 Valve Spring 1
51F 05081 Valve Spring Guide 1
56A 06258 O-Ring 3
Oil Seal Kit - #09584
Item Part # Description Qty .
32 05058 Radial Shaft Seal 3
33A 05056 O-Ring 3
Discharge Valve Kit - #09588
Item Part # Description Qty .
52 B 05084 Discharge Valve Seat 1
52 C 05079 V alve Plate 1
52D/56A 06258 O-Ring 2
52 E 05080 Valve Spring 1
52F 05081 V alve Spring Guide 1
GP8155-R TOOL LIST AND T ORQUE SPECIFICATIONS
Item Part # Description Torque Ft-Lbs (NM) T ool Needed
17 05038 Hexagon Socket Screw 64 (87) 10mm Allen Wrench
24 05047 Connecting Rod Hex. Hd. Socket Screw 37 (50) 8mm Allen Wrench
33B 05054 Clip Ring N/A Industrial Snap Ring Pliers
36C 05062 Tension Screw 30 (40) 16mm Socket
49A 05073 Hexagon Nut (Manifold) 265 (360) 30mm Socket
51-52 05076-05082 Valve Assemblies N/A Valve Puller (p/n 07662) Included
w/pump
58 05087 Hexagon Socket Screw 132 (180) 12mm Allen Wrench
K5 07381 Hexagon Socket Screw N/A 8mm Allen Wrench
GP8155-R TROUBLESHOOTING
Problem Cause Solution
Pressure Drops, water leaks V -sleeves leak Replace V-sleeves, check surface of
plunger
Pressure drops, pump gets loud Discharge or suction valve leaks Replace valve(s)
Steam formation (Cavit ation) Reduce suction height, reduce flow
resistance in inlet line, clean inlet
filter, lower water temperature.
Irregular pressure Worn V alves Examine valves
O-ring on valves or inlet valve
adapter leaks Examine O-rings, check valve
casing for unevenness on the
sealing surfaces
Oil leaks at visible part of plunger Gear sealing is leaking Examine seals and running surface
of plunger
Dirty, milk-colored or frothy oil Water has mixed with oil Replace oil immediately, find & fix
the cause
Oil leakage on the crankshaft Shaft seal ring leaks Check seal and shaft
Noise increases without the loss Worn bearing Dismantle 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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