Giant View Manual

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Giant View Manual | Manualzz

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.

11

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.

12

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.

13

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).

14

GP8155-R, GP8160-R and GP8165-R PUMP DIMENSIONS - INCHES (MM)

15

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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