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Series
GP8155-R
GP8160-R
GP8165-R
REVERSE GEARBOX SERIES
Triplex Ceramic
Plunger Pump
Operating Instructions
Repair and Service Manual
Updated 03/15
Contents:
Installation Instructions:
Operating Instructions:
GP8155 Pump Specifications:
GP8160 Pump Specifications:
GP8165 Pump Specifications:
Exploded View:
Parts List:
Repair Kits:
Tool List/Torque Specifications/
Troubleshooting Chart:
Repair Instructions:
Dimensions:
Warranty Information: page 2 page 3 page 4 page 5 page 8 page 6 page 7 page 9 page 10 pages 11-14 page 15 back page
INSTALLATION 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.
Gear on right side from behind pump = optimal rotation: to the left
Gear on left side from behind pump = optimal rotation: to the right
The preferred/optimal direction of rotation ensures the motion of the conrods correctly distributes the oil onto the crosshead guides - which is a particular advantage where continuous operation is involved.
2. Cavitation and/or compresssion of gases will lead to uncontrollable pressure spikes which can damage the pump and parts as well as cause injury to the operator or people nearby. The inlet to the pump should be sized for the flow rate of the pump with no unnecessary restrictions that can cause cavitation.
If these pumps are to be operated at temperatures in excess of 86 o F (30 o C), be sure to contact Giant
Industries. At higher temperatures it is important to insure a positive head (NPSH) to the pump to prevent cavitation. As the inlet temperature increases, the cooling system becomes less effective. For fluid temperatures above 120 °F (50 °C), an independent colling system should be installed.
The pump can also be run against the recommended direction of rotation if operated periodically or at reduced pressure. If so, the pump has to be run in this direction to smooth out bearing areas. This is done by a one-time operation at zero pressure for at least
30 minutes; thereafter the pressure must be slowly increased over the next hour to the desired max. operating pressure after which the pump is then run at this pressure. The oil temperature is to be checked during this procedure.
During operation, all rotating parts, shaft(s) and coupling, must be covered by a protective guard. Plunger area must have the cover plate (30) secured in place. Do not step or place weight on the cover plate (30).
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.
Teflon tape should be used to seal all joints.
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.
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 (i.e. constant dripping).
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.
5. Crankshaft rotation on Giant Industries, Inc.
GP8100-R series pumps should be made in the direction designated by the black arrows on the pump gearcase. This is to ensure proper lubrication. 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 pages 4-6.
Failure to comply with any of these conditions invalidates warranty
2
OPERATING INSTRUCTIONS
IMPORTANT OPERATING INSTRUCTIONS
Failure to comply with any of these conditions invalidates 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 gear lube oil (ISO VG 220 GL4), 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 1000 hours or less depending on operating conditions. In either case, the oil should be changed once per year.
Run pump for one (1) min at ZERO PSI before operating under pressure.
When operating in high humidity or wide temperature fluctuations, oil must be changed if condensate or frothy oil occurs in crankcase.
2.Pump operation must not exceed rated pressure, volume or RPM. A pressure relief device must be installed in the discharge of the system to prevent the rated pressure from exceeding 10%. NPSH values must be observed.
3. Giant Triplex Plunger Pumps are suitable for pumping clean water and other non-aggressive or nonabrasive liguids with a specific weight close, or equal, to water. All media to be filtered to 200 microns.
Before pumping other media, such as acids, alkalines, abrasive, explosive or toxic fluids, Giant Industries,
Inc. must be consulted and approval - if granted - provided in writing. It is the responsibility of the equipment operator and/or end user to ensure that all pertinent safety regulations are adhered to.
4. Run the pump dry approximately 10 seconds to drain the water before exposure to freezing temperatures.
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.
To empty the cooling circuit, remove the Ljoints (K11) on the pump head (50). Blow out the circuit liquid at the joint connection (K11/K7) using compressed air.
5. Inlet pressure not to exceed
29 PSI (2 bar) when using the integrated oil cooling system. If using the separate cooling system, the inlet pressure can be a maximum of 145 PSI (10 bar). Make sure that the suction pulsation is sufficiently dampened; water column resonance must be avoided.
6. The torque tension on the valve casing nuts
(49A) should be checked after approximately
200 operating hours. Pump must be at zero pressure. See page 10 for torque values.
3
Specifications
GP8155-R Series
U.S. (Metric)
Volume ............................................................. Up to 75.5 GPM ...... (285 LPM)
Discharge Pressure ......................................... Up to 3000 PSI ....... (200 bar)
Crankshaft Speed .............................................................................. Up to 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 .................................................................................... See Page 2
Temperature of Pumped Fluids ....................... Up to 86 o F .............. (30 o C)
Inlet Ports .......................................................................................... (2) 3” BSP
Discharge Ports ................................................................................. (2) 1-1/4” BSP
Weight ............................................................. 794 lbs. .................... (360kg)
Crankcase Oil Capacity ................................... 4.2 Gal. ................... (16.0 liters)
Fluid End Material ............................................ Nickle plated Spheroidical Cast Iron
(The specifications above are based on maximum pressure and maximum RPM for
intermittant duty using cold water.)
Model Gear Ratio Input Speed
GP8155-1.28-R ................................1.28:1 ....................................................740 RPM
GP8155-2.6-R ...................................2.6:1 ....................................................1500 RPM
GP8155-3.1-R ...................................3.1:1 ....................................................1800 RPM
GP8155-3.8-R ...................................3.8:1 ....................................................2200 RPM
GP8155-4.5-R ...................................4.5:1 ....................................................2600 RPM
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 HORSEPOWER
REQUIREMENTS
RPM GPM 500 PSI 1000 PI 2000 PSI 3000 PSI
300 39
400 52
500 65
13.9
18.6
23.2
580 75.5
27.0
27.9
37.1
46.4
53.9
55.7
74.3
92.9
107.9
83.6
111.4
139.3
161.8
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
SPECIAL NOTE:
The theoretical gallons per revolution (gal/rev) is 0.130.
To find specific outputs at various RPM, use the formula:
GPM = 0.130 x RPM
4
Specifications
GP8160-R Series
U.S. (Metric)
Volume ............................................................. Up to 90 GPM ......... (341 LPM)
Discharge Pressure ......................................... Up to 2500 PSI ....... (172 bar)
Crankshaft Speed .............................................................................. Up to 580 RPM
Inlet Pressure .................................................. Up to 29 PSI ........... (2.0 bar)
Plunger Diameter ............................................. 2.36” ......................... 60mm
Plunger Stroke ................................................. 2.83” ......................... 72mm
Crankshaft Diameter ........................................ 2.76” ......................... 70mm
Key Width ........................................................ 0.55” ......................... 14mm
Crankshaft Mounting ......................................................................... Either side
Shaft Rotation .................................................................................... See Page 2
Temperature of Pumped Fluids ....................... Up to 86 o F .............. (30 o C)
Inlet Ports .......................................................................................... (2) 3” BSP
Discharge Ports ................................................................................. (2) 1-1/4” BSP
Weight ............................................................. 794 lbs. .................... (360kg)
Crankcase Oil Capacity ................................... 4.2 Gal. ................... (16.0 liters)
Fluid End Material ............................................ Nickle plated Spheroidical Cast Iron
(The specifications above are based on maximum pressure and maximum RPM for
intermittant duty using cold water.)
Model Gear Ratio Input Speed
GP8160-1.28-R ................................1.28:1 ....................................................740 RPM
GP8160-2.6-R ...................................2.6:1 ....................................................1500 RPM
GP8160-3.1-R ...................................3.1:1 ....................................................1800 RPM
GP8160-3.8-R ...................................3.8:1 ....................................................2200 RPM
GP8160-4.5-R ...................................4.5:1 ....................................................2600 RPM
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.
GP8160-R HORSEPOWER
REQUIREMENTS
RPM GPM 500 PSI 1000 PSI 2000 PSI 3000 PSI
300 47
400 62
500 78
580 90
16.8
22.1
27.9
32.1
33.6
44.3
55.7
64.3
67.1
88.6
111.4
128.6
83.9
110.7
139.3
160.7
SPECIAL NOTE:
The theoretical gallons per revolution (gal/rev) is 0.155.
To find specific outputs at various RPM, use the formula:
GPM = 0.155 x RPM
5
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
Specifications
GP8165-R Series
U.S. (Metric)
Volume ............................................................. Up to 105 GPM ....... (400 LPM)
Discharge Pressure ......................................... Up to 2000 PSI ....... (140 bar)
Crankshaft Speed .............................................................................. Up to 580 RPM
Inlet Pressure .................................................. Up to 29 PSI ........... (2.0 bar)
Plunger Diameter ............................................. 2.55” ......................... 65mm
Plunger Stroke ................................................. 2.83” ......................... 72mm
Crankshaft Diameter ........................................ 2.76” ......................... 70mm
Key Width ........................................................ 0.55” ......................... 14mm
Crankshaft Mounting ......................................................................... Either side
Shaft Rotation .................................................................................... See Page 2
Temperature of Pumped Fluids ....................... Up to 86 o F .............. (30 o C)
Inlet Ports .......................................................................................... (2) 3” BSP
Discharge Ports ................................................................................. (2) 1-1/4” BSP
Weight ............................................................. 794 lbs. .................... (360kg)
Crankcase Oil Capacity ................................... 4.2 Gal. ................... (16.0 liters)
Fluid End Material ............................................ Nickle plated Spheroidical Cast Iron
(The specifications above are based on maximum pressure and maximum RPM for
intermittant duty using cold water.)
Model Gear Ratio Input Speed
GP8165-1.28-R ................................1.28:1 ....................................................740 RPM
GP8165-2.6-R ...................................2.6:1 ....................................................1500 RPM
GP8165-3.1-R ...................................3.1:1 ....................................................1800 RPM
GP8165-3.8-R ...................................3.8:1 ....................................................2200 RPM
GP8165-4.5-R ...................................4.5:1 ....................................................2600 RPM
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.
GP8165-R HORSEPOWER
REQUIREMENTS
RPM GPM 500 PSI 750 PSI 1000 PSI 2000 PSI
300 54
400 72
500 91
18.6
24.8
31.4
580 105 36.2
27.9
37.2
47.1
54.3
37.2
49.7
62.8
72.4
74.5
99.3
125.5
144.8
SPECIAL NOTE:
The theoretical gallons per revolution (gal/rev) is 0.181.
To find specific outputs at various RPM, use the formula:
GPM = 0.181 x RPM
6
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
Pump Repair Kits - GP8155-R, GP8160-R, GP8165-R
Plunger Packing Kit - GP8155
# 09616
Item Part # Description
38A 13286 O-Ring
38B 05281 Support Ring
39A 05066 O-Ring
40 07723 Seal Ring
42 05277 Sleeve
Qty.
6
6
3
3
9
Plunger Packing Kit - GP8160
# 09617
Item Part # Description
38A 06667 O-Ring
39A 05066 O-Ring
40 05067 Seal Ring
42 05069 Sleeve
Qty.
6
3
3
9
Plunger Packing Kit - GP8165
# 09586
Item Part # Description
38A 06667 O-Ring
39A 05066 O-Ring
40 06996 Seal Ring
42 06997 V-Sleeve
Qty.
6
3
3
9
Inlet Valve Kit
#09587
Item Part # Description
51B 05078 Inlet Valve Seat
51C 05079 Valve Plate
51D 07658 O-Ring
Qty.
1
1
1
51E 05080 Valve Spring 1
51F 05081 Valve Spring Guide 1
56A 06258 O-Ring 1
Discharge Valve Kit
#09588
Item Part # Description Qty.
52B 05084 Discharge Valve Seat 1
52C 05079 Valve Plate
52D 06258 O-Ring
52E 05080 Valve Spring 1
52F 05081 Valve Spring Guide 1
56A 06258 O-Ring
1
2
1
Oil Seal Kit
#09584
Item Part # Description Qty.
32 05058 Radial Shaft Seal 3
33A 05056 O-Ring 3
7
EXPLODED VIEW - GP8155-R, GP8160-R, GP8165-R
8
Parts List - GP8155-R, GP8160-R, GP8165-R
21A
21B
21C
22
23
24
25
28
29
29A
05047
05048
05049
05051
07408
29B 05383
07102
12256
22929
05036
05037
05038
05039
05765
05766
05658
05659
05042
05043
05113
05660
05661
14
16
17
18
19
19A
20
21
6
7
8
9
10
11
12
13
2
3
4
5
Item Part
1 05651
06893
05652
05653
05654
05655
05656
05035
01009
05657
40
41
41
41
42
42
38A
38B
39
39
39
39A
40
40
36B
36B
36C
36D
36E
38
38
38A
32
33
33A
33B
33C
34
36A
36B
29C
29D
30
30A
30B
30C
30D
31
05662
05381
05052 Cover Plate
07225-0100 Hexagon Screw
13136
08280
05050
07623
06667
05281
05275
05065
05116
05066
07723
05067
06996
05276
05068
05117
05277
05069
05058
05055
05056
05054
05059
05060
05063
05280
05061
05115
05062
07665
06900
05283
05064
13286
Description
Crankcase
Qty
1
Oil Filler Plug Assy with Vent 1
Rear Foot for Crankcase
Front Foot for Crankcase
Hexagon Socket Screw
Hexagon Socket Screw
Plug 3/8 for Oil Dipstick
Oil Dipstick Assy
O-Ring
Plug M33 X 1.5
O-Ring
Plug 3/8” BSP
Copper Washer
Bearing Cover Closed
O-Ring 1
Hexagon Socket Screw M12 8
Spring Ring
Flange
4
4
2
2
4
1
1
3
1
1
1
1
Hexagon Socket Screw
Tapered Roller Bearing
Tapered Roller Bearing
Fitting Disc
Fitting Disc
Fitting Disc
Crankshaft For Turned Gear 1
Fitting Key
3
3
1
3
6
1
8
1
Conn-rod Assy
Crosshead c/w Plunger
Crosshead Pin
Hexagon Screw
Hexagon Nut
Bracket 2 for Cooling Hose
Support Clamp
Bracket 1 for Cooling Hose
Grommet
Washer
Splash Cover
Eye Bolt
Radial Shaft Seal
Seal Retainer
O-Ring
Clip Ring
Fitting Disc
Oil Shield
Plunger Pipe Cover
Plunger, GP8155
Plunger, GP8160
Plunger, GP8165
Tension Screw
Copper Washer
Centering Sleeve
Seal Case, GP8155 3
Seal Case, GP8160, GP8165 3
O-Ring, GP8155
O-Ring, GP8160, GP8165
Support Ring, GP8155 Only 6
Seal Sleeve, GP8155
6
6
Seal Sleeve, GP8160
Seal Sleeve, GP8165
O-Ring
Seal Ring, GP8155
Seal Ring, GP8160
Seal Ring, GP8165
Pressure Ring, GP8155
Pressure Ring, GP8160
Pressure Ring, GP8165
Sleeve, GP8155
Sleeve, GP8160
3
3
3
3
4
3
9
1
5
5
1
1
2
2
6
2
3
3
1
3
3
3
3
3
3
3
3
3
3
3
3
3
9
9
3
3
3
3
3
3
73
74
75
75A
76
77
78
79
66
67
67A
68
69
69
70
72
57A
58
59
59A
60
61
62
62A
52B
52C
52D
52E
52F
56
56A
57
K7
K8
K9
K10
K11
K12
K13
K14
K15
K16
80
81
K1
K2
K3
K4
K5
K6
05672
05026
05027
05028
05029
07381
08041
05030
06272
07109
05031
05032
05033
05402
05403
05404
05405
05664
05341
05665
05767
05666
07614
05667
05428
05668
05669
05670
05432
05671
05025
07662
01010
51A
51B
51C
51D
51E
51F
52
52A
45
45
49
49A
50
50A
50B
51
Item Part
42
43
43
43
45
06997
05278
05070
05118
05279
05071
05119
05072
05073
05074
13162
05075
04186
04166
05078
05079
07658
05080
05081
04188
04166
05084
05079
06258
05080
05081
Description
Sleeve, GP8165
Qty
9
Sleeve Support Ring, GP8155 3
Sleeve Support Ring, GP8160 3
Sleeve Support Ring, GP8165 3
Seal Tension Spring, GP8155 3
3 Seal Tension Spring, GP8160
Seal Tension Spring, GP8165 3
Stud Bolt
Hexagon Nut
Valve Casing
Centering Stud
Discharge Casing
Suction Valve Assy.
Spring Tension Cap
Suction Valve Seat
Valve Plate
O-Ring
Valve Spring
Valve Spring Guide
Discharge Valve Assy
Spring Tension Cap
Discharge Valve Seat
Valve Plate
O-Ring
Valve Spring
05085
06258
05086
Valve Spring Guide
Discharge Valve Adaptor
O-Ring
Pressure Spring
07210-0100 Pressure Spring
05087
07109
06272
06909
05088
05302
06934
05663
1
2
8
8
Hexagon Socket Screw
Plug, 1/2” BSP
Copper Seal
Plug, 1-1/4” BSP
Plug G3
Plug G1/4
Copper Gasket
Gear Cover
Hexagon Screw
Washer
Cylinder Pin
10
4
Gear Wheel Set (2200 RPM=3.8) 1
1
1
2
2
3
3
3
12
6
6
1
10
3
3
6
3
3
3
3
3
3
3
3
3
3
3
1
3
Gear Wheel Set (2600 RPM=4.5) 1
Fitting Key
Hexagon Screw
Shaft Seal Ring for Gear
Self-Aligning Roller Bearing
Roller Bearing
1
1
Fitting Disc
Gear Seal
Flange c/w Gear
Oil Cooler (Items K1 - K16)
Valve Puller (Not Shown)
Hexagon Socket Screw M8
Hexagon Socket Screw
Cooling Vane Plate
Seal for Gear Cover
Gear Cover
Hexagon Hd Cntrsnk Screw
Hexagon Socket Screw
Washer
Connection for Oil Cooler
Copper Seal
Plug, 1/2” BSP
Connecting Branch
U-Joint Connector c/w Nut
Tube for Cooler
Hose Clamp
Hose Guard
Hose Coupling Nut
Flat Gasket
1
1
2
1
1
1
1
1
4
2
3
2
1
4
2
3
1
6
8
8
1
8
1
2
1
9
9
Torque Specifications and Troubleshooting
GP8155-R, GP8160-R, GP8165-R
TOOL LIST AND TORQUE SPECIFICATIONS
Item Part #
17 05038
Description
Hexagon Socket Screw
Torque Ft-Lbs (NM)
64 (87)
24 05047 Connecting Rod Hex. Hd. Socket Screw 37 (50)
33B 05054 Clip Ring N/A
Tool Needed
10mm Allen Wrench
8mm Allen Wrench
Industrial Snap Ring Pliers
36C 05062
49A 05073
51 & 05076 &
52 05082
58 05087
K5 07381
Tension Screw
Hexagon Nut (Manifold)
Valve Assemblies
Hexagon Socket Screw
Hexagon Socket Screw
30 (40)
265 (360)
N/A
132 (180)
N/A
16mm Socket
30mm Socket
Valve Puller (p/n 07662) included w/pump
12mm Allen Wrench
8mm Allen Wrench
Problem
Pressure Drops, water leaks
Pressure drops, pump gets loud
Irregular pressure
Oil leaks at visible part of plunger
Dirty, milk-colored or frothy oil
Oil leakage on the crankshaft
Noise increases without the loss
TROUBLESHOOTING
Cause
V-sleeves leak
Discharge or suction valve leaks
Steam formation (Cavitation)
Worn Valves
O-ring on valves or inlet valve adapter leaks
Gear sealing is leaking
Water has mixed with oil
Shaft seal ring leaks
Worn bearing
Solution
Replace V-sleeves, check surface of plunger
Replace valve(s)
Reduce suction height, reduce flow resistance in inlet line, clean inlet filter, lower water temperature.
Examine valves
Examine O-rings, check valve casing for unevenness on the sealing surfaces
Examine seals and running surface of plunger
Replace oil immediately, find & fix the cause
Check seal and shaft
Dismantle gear, examine all parts, 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.
10
GP8155-R, GP8160-R and GP8165-R PUMP REPAIR INSTRUCTIONS
Valve Inspection and Repair
1) Remove socket head cap screws (58)
2) Lift discharge casing
(50B) up and away.
3) Take out pressure springs
(57A). Pull out assembled valves (51 & 52) with valve puller.
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). Remove spring tension cap.
Takeout springs (51E, 52E) and valve plate (51C, 52C). Check sealing surfaces of valve plates (51C &
52C) and valve seats (51B & 52B) 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 tapping 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 132 Ft-lbs. (180
Nm); check torque tension after 8-10 operating hours.
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 tap 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.
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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.
GP8155-R, GP8160-R and GP8165-R PUMP REPAIR INSTRUCTIONS
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.
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.
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. (40 NM)
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).
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 265 Ft.-lbs. (360 NM). Follow pattern below.
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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.
GP8155-R, GP8160-R and GP8165-R PUMP REPAIR INSTRUCTIONS
To Dismantle Crankcase Gear
11) Take 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 radial shaft 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)
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.
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 (22) out of the crankcase (1) 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.
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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. (87 NM).
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. (50 NM). The shaft should turn easily.
Connecting rods must be able to move slightly sideways on the stroke journals.
GP8155-R, GP8160-R and GP8165-R PUMP REPAIR INSTRUCTIONS
15) Replace seal retainer (33), radial shaft 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) is compensated by using 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 nuts (49A) evenly and cross-wise to 265 Ft-lbs.
(360 Nm).
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 (22) so that the pinion (69) together with the bearing (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.
For Repair or Inspection of Reduction Gear
Remove screws (67). Pull off gear cover (66) by screwing two (2) screws into both thread 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 hammer.
Check the surfaces of the conn-rods (24), crankshaft (22) and crossheads (25). Check the surfaces of the crosshead guides in the crankcase for any uneveness.
Reassemble in reverse order. Adjust axial play (clearance) on the crankshaft to a minimum of 0.004” (0.1mm)
/ max. .006” (0.15mm) using shims (20C). Press the bearing ring (21) past the clip ring groove. Assemble in the clip ring and insert the crankshaft from the other side, then press in the roller bearing 20). The shaft should turn easily with little clearance. Replace the bearing cover (14) and tighten the screws (17) at 64 Lb-ft
(87 Nm). Mount conn-rod halves into their exact original position and tighten to 37 Lb-ft (50 Nm).
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GP8155-R, GP8160-R and GP8165-R PUMP DIMENSIONS - INCHES (MM)
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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 car wash applications, the discharge mani folds 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 applica tions, are warranted for five years from the date of 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 prior to the return to Giant Industries of all products under warranty consideration. Call (419)-531-4600 or fax (419)-531-6836 to obtain an R.G.A. number.
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 WAR-
RANTIES 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., P.O. Box 3187, Toledo, Ohio 43607
PHONE (419) 531-4600, FAX (419) 531-6836, www.giantpumps.com
Copyright 2014 Giant Industries, Inc.
03/15 GP8100-R.indd
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