Giant GP8065 User's Manual
Contents
1. 39A 05066 O Ring 40 07723 Seal Ring 42 05277 V Sleeve GP8060 09617 Item Part Description 38A 06667 O Ring 39A 05066 O Ring 40 05067 Seal Ring 42 05069 V Sleeve GP8065 09586 Item Part Description 38A 06667 O Ring 39A 05066 O Ring 40 06996 Seal Ring 42 06997 V Sleeve Inlet Valve Kit 09587 Item Part Description Qty 53B 05078 Inlet Valve Seat 1 53C 05079 Valve Plate 1 53D 07658 O Ring 1 53E 05080 Valve Spring 1 53F 05081 Valve Spring Guide 1 Discharge Valve Kit 09588 Item Part Description Oty 54B 05084 Discharge Valve Seat 54C 05079 Valve Plate 1 54D 06258 O Ring 1 1 S4E 05080 Valve Spring S4F 05081 Valve Spring Guide GP8055 GP8060 GP8065 TOOL LIST AND TORQUE SPECIFICATIONS ITEM TORQUE Ft Ibs NM TOOL NEEDED 36C Valve puller p n 07662 included with pump 12mm allen wrench GP8000 Trouble Shooting Problem Cause Solution S Pressure drops water leaks V sleeves leak Replace V sleeves examine surface of olunger Pressure drops pump Steam formation cavitation Reduce suction height reduce flow resistance becomes loud in inlet line clean inlet filter lower water temperature adapter leaks unevenness on the sealing surfaces plunger Oil leakage on the crankshaft Shaft seal ring leaks Check seal and shaft Noise increases without loss of Worn bearing Dismantle gear examine all parts replace pressure worn parts check oil level If service life was too short check for excess2. GP8050 GP8060 GP8065 SERIES DIMENSIONS mm 880 I 545 E Eoo Discharge al x T 2x 1 1 4 BSP NI a 1 S E TH TI L h m4 rT PS my Le a Centring 7 _ N Keyway B20 x 12 x 110 DR M12 DIN 332 70 DIN 6885 Blatt 1 a 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 Defects caused by ne
3. Pressure Ring GP8065 Pressure Ring GP8060 Pressure Ring GP8055 V Sleeve GP8065 V Sleeve GP8060 V Sleeve GP8055 Sleeve Support Ring GP8065 Sleeve Support Ring GP8060 Sleeve Support Ring GP8055 Seal Tension Spring GP8065 Seal Tension Spring GP8060 Seal Tension Spring GP8055 Stud Bolt Hexagon Nut Valve Casing Centering Stud Discharge Cas ng 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 Valve Spring Guide Discharge Valve Adaptor O Ring Pressure Spring Pressure Spring Hexagon Socket Screw Plug G1 2 Copper Seal Plug G1 1 4 Plug G3 Plug G1 4 Copper Gasket Disc for Crankshaft Hexagon Screw Cooling Vane Plate Seal for Gear Cover Gear Cover Hexagon Head Countersunk Screw Hexagon Socket Screw Washer Connection for Oil Cooler Copper Seal Plug G1 2 Connecting Branch Hose Adaptor Tube for Cooler Hose Clamp Oty DD DD DD DD DA DD WW WW WW WWW WR N e WO OW WW WW DW OO OO OO W WW N NOR RR OO me e Ke eR FNP WNADVAK DA AW 00 GP8055 GP8060 GP8065 PUMP REPAIR KITS Plunger Packing Kits Oil Seal Kit 09221 GP8055 09616 Item Part Description Qty Item Part Description 33A 05056 O Ring 3 38A 13286 O Ring 33B 05057 Compact Ring 3 38B 05281 Support Ring 33C 05058 Radial Shaft Seal 3
4. GP8055 GP8060 GP8065 PUMP REPAIR INSTRUCTIONS ra 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 neces sary replace together with seals 40 and 42 Clean all parts New parts should be lightly coated with silicon grease before installation Inert the seal unit 40 41 42 43 into the sleeve Push the ceramic plunger carefully through the seals from the crank case 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 if necessary secure 2 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 8 Coat the seal sleeve 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 per hand until the plunger 25 rests against the plunger pipe Tight
5. 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 3 6 6 Before beginning operation of your pumping system remember Check that the crankcase and seal areas have been properly lubricated per recom mended 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 Important 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 nally remember that high pressure operation n a pump system has many advantages But if itis 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 tempera tures 5 The pump and cooling system must be emptied 1f there is a danger of frost Note that travel wind for example can cause water in pumps fitted on open vehicles to freeze even 1f the outside temperature is above freezing point To empty the cooling circuit remove the L joints K11 on th
6. use of a shut off gun 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 Indus tries 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 condi ions 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 Oamala oil 220 or Texaco Meropa 220 Crankcase oil should be changed after the first 50 hours of operation then at regular intervals of 500 hours or less depending on operating conditions 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 5 Crankshaft rotation on Giant Industries Inc pumps should be made in the direction designated by the arrows on the pump crankcase Reverse rotation
7. For Gearbox Pumps Crankshaft Spacer Ring Fitting Key Conn rod Assy Crosshead c w Plunger Crosshead Pin Hexagon Screw Cover Plate Hexagon Screw Grommet Washer Splash Cover Eye Bolt Radial Shaft Seal Compact Ring Seal Retainer O Ring Clip Ring Fitting Disc Oil Shield Cover for Plunger Pipe GP8060 GP8065 Plunger Pipe GP8065 Plunger Pipe GP8060 Plunger Pipe GP8055 Tension Screw Copper Washer Centering Sleeve Seal Case GP8060 GP8065 Seal Case GP8055 O Ring GP8060 GP8065 O Ring GP8055 Support Ring GP8055 Only Seal Sleeve GP8065 Seal Sleeve GP8060 Seal Sleeve GP8055 O Ring Seal Ring GP8065 Seal Ring GP8060 Seal Ring GP8055 Qty WBWWWWWWWE SU Um m DD wwVeHme HH mem Sa rm nm DD WW WWW OW ON DW DD DD DD DD DD W W LO Item 41 41 41 42 42 42 43 43 43 45 45 45 49 49A 50 50A 50B 51 51A 51B 51C 51D SIE 51F 52 52A 52B 52C 52D 52E 52F 56 56A 57A 58 59 59A 60 61 62 62A 66 67 K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 Kill K12 K13 Part 05117 05068 05276 06997 05069 05277 05118 05070 05278 05119 05071 05279 05072 05073 05074 13162 05075 05076 05077 05078 05079 07658 05080 05081 05082 05077 05084 05079 06258 05080 05081 05085 06258 05086 06078 05087 07109 07661 06909 05088 06090 06934 05122 13358 05026 05027 05028 05029 07381 08041 05030 07661 07109 05031 05032 05033 05034 Description
8. ISCLAIMED AND EXCLUDED BY THE MANUFACTURER GIANT INDUSTRIES INC 900 N Westwood Ave P O Box 3187 Toledo Ohio 43607 419 531 4600 FAX 419 531 6836 www giantpumps com Copyright 2007 Giant Industries Inc 3 07 GP8050 GP8060 GP8065 PMD
9. Triplex Ceramic Models ame ware GP8055 GP8060 GP8065 Contents Installation Instructions page 2 Pump Specifications page 3 5 Exploded View Parts List pages 6 Repair Kits Tool List Torque Specifications page 8 Troubleshooting Chart page 8 Repair Instructions pages 9 11 Dimensions back page Updated 3 07 Warranty Information back page INSTALLATION INSTRUCTIONS Installation of the Giant Industries Inc pump is nota 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 Indus tries 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 pumps are to be operated at temperatures in excess of 140 F it is important to insure a positive head 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
10. e We recommend a 1 1 service factor be specified when selecting an electric motor as the power source To compute specific pump horse power requirements use the following formula SPECIAL NOTE GPMXPSI _ The theoretical gallons per revolution gal rev is 0 130 1400 HP To find specific outputs at various RPM use the formula GPM 0 130 x RPM Specifications Model GP8060 US Metric VORDER Up to 90 GPM 341 LPM Discharge Pressure Up to 2500 PST u 172 bar E 0151 51 I E T IEAA AEEA Up to 580 RPM 580 RPM Inlet Pre Unseren Opto 29 PS besiess 2 0 bar Plunger DITE eenn LI E 60mm Plunger Stroke nennen DOO EO 72mm Crankshaft Diameter sauna 210 sen 70mm Key caesar etree ctevceed aesesaccasseacnoscuce ee ODD edeesarees cessed 14mm Crank SVG VOU INS ssia iee en a Either side Shaft Rotation sta ssc diosa cuanoctewennsecedthuncs thu sokduexueunacnssonssntseueceaniescabedsor Top of pulley towards manifold Temperature of Pumped Fluids Up to 140 Teaser 60 C Inlet PO e A A 2 3 BSPP Disc Hanse POS e ee 2 1 1 4 BSPP NVC I ea TOS ID nen 320kg CrankC ase Oil Capacity ren Ile 12 5 liters Fluid End Martial sea 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 HORSEPOWER RATINGS GP8060 HORSEPOWER REQUIREMENTS The rating shown are the p
11. e 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 8 for torque values Specifications Model GP8055 U S Metric VO De ee Up to 75 5 GPM 285 LPM Discharge Pressure ses Up to 3000 PSI 200 bar PE r E E Up to 580 RPM 580 RPM Inlet PIC SSUES essen Up to 29 PSI 2 0 bar Plonger Dial nee ll ee 55mm Plunger SIITOR een DSO essen 72mm Crank Sal Diamete eine I E 70mm Key Width cececccceeseeeseeseeeeeeeeeeeseeeeeeeeens UII semeri 14mm Crankshaft MOUDUNE ee as Either side SPUER O O ee OSR Top of pulley towards manifold Temperature of Pumped Fluids Up to 140 F 60 C MC PO nenne ee 2 3 BSPP Die IE Tg e PON eee ee en ee ae mt nn TT merece 2 1 1 4 BSPP NY CIC 1 RENNEN REISE EEHREERPLTERSERIEENCEEN TE TOD TDS dessen 320kg Crank case Oil Capacity ers eo 1 amp I T 12 5 liters Fluid End Material nenn 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 HORSEPOWER RATINGS GP8055 HORSEPOWER REQUIREMENTS Te power requirements for the pump Gas engine power outputs must be approximately twice the pump power requirements shown abov
12. en the tension screw at 30 Ft Ibs 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 O ring 39A in to the seal sleeve 39 Replacing Valve Casing 9 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 Ibs 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 10 GP8055 GP8060 GP8065 PUMP REPAIR INSTRUCTIONS To Dismantle Crankcase Gear 10 Take out plungers and seal sleeves as described 11 Remove the connecting rod screws 24 above Drain the oil by taking off the plug 12 After removing the clip ring 33B lever out the seal retainer Connecting rods are marked 1 to 3 33 with a screwdriver Open hose adaptor K11 and for identification Do not twist connecting rod remove gear cover K3 Remove the cooling vane plate halves or interchange them When reassembling K1 by removing the screws K4 the connecting rod must be fitted in their exact Original position on the crankshaft journals 12 Push connecting rod hal
13. gligence or fault of the buyer or third party Normal wear and tear to standard wear parts Use of repair parts other than those manufactured or authorized by Giant Improper use of the product as a component part Changes or modifications made by the customer or third party The operation of pumps and or accessories exceeding the specifications set forth in the Operations Manuals provided by Giant Industries Inc DPN 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 REPRESENTA TION EXPRESS OR IMPLIED INCLUDING WITHOUT LIMITATION ANY WARRANTIES OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE AND ALL SUCH WARRANTIES ARE HEREBY D
14. ower requirements for the pump Gas engine power outputs must be approximately twice the pump power requirements shown above 580 90 32 1 643 128 6 160 7 We recommend a 1 1 service factor be specified when selecting an electric motor as the power source To compute specific pump horse power requirements use the following formula SPECIAL NOTE GPMXPSI _ HP The theoretical gallons per revolution gal rev is 0 155 1400 To find specific outputs at various RPM use the formula GPM 0 155 x RPM Specifications Model GP8065 USS Metric 6 U1 ee Up to 105 GPM 400 LPM Discharge Pressure ses Up to 2000 PSI 140 bar DCE Cl e EL EETEUNUUR UONRERSURFEEEEOREEEE Up to 580 RPM 580 RPM Wee oct i ce TE Up to 29 PSI zus 2 0 bar Plonger Diower ts et P a T EEE E 65mm Pin ei SEONG een ZOO EE 72mm Crankshaft Diameter esse een MID merke 70mm Key Wider VII einen 14mm Crank shall Ty LOUNGES nee ee Either side SHAR RO ION een ee ee Top of pulley towards manifold Temperature of Pumped Fluids Up to 140 F ren 60 C ME PO nenne TE E E EAEE E 2 3 BSPP Disc ha2 Ton eee E E 2 1 1 4 BSPP Wet 1 aea TOD MOS c 320kg Crankcase Oil Capacity anne De 6 1 N 12 5 liters Fluid End Material nen 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
15. strain or whether lubrication intervals were too long Only specified lubricants are to be used GP8055 GP8060 GP8065 PUMP REPAIR INSTRUCTIONS Valve Inspection and Repair 1 Remove bolts 58 2 Remove discharge 3 Take out pressure springs casing 50B up and away 57A Pull out assembled valves 51 amp 52 with fitting tool 4 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 Tighten caps 58 at 133 Ft lbs 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 neces sary carefully tap the valve casing 50 past the centering stud 50A of the seal assembly and check for any 6 Remove tension screw 36C and take seal sleeve 39 together with all mounted parts out of the drive Pull plunger pipe out using a rubber hammer IMPORTANT If necessary support the valve casing by resting it on wooden blocks or by using a pulley damage Carefully remove seal rings 40 and sleeves 42 with a screw driver
16. the limits specified above HORSEPOWER RATINGS GP8065 HORSEPOWER REQUIREMENTS eisen enge requirements for the pump Gas engine power outputs must be approximately twice the pump power requirements shown above We recommend a 1 1 service factor be specified when selecting an electric motor as the power source To compute specific pump horse power requirements use the following formula SPECIAL NOTE GPM X PSI _ The theoretical gallons per revolution gal rev is 0 181 1400 HP To find specific outputs at various RPM use the formula GPM 0 181 x RPM Exploded View GP8050 GP8060 GP8065 14A 15 16 17 18 19 20 21 21A 21B 2IC 22 22 22A Part 05024 06912 05035 06225 07109 07182 05036 05111 05112 05037 05038 05039 05040 05041 05044 05042 05043 05113 05045 05114 05046 05104 05047 05048 05049 05057 05052 07225 0100 13136 05053 05050 07623 05058 05057 05055 05056 05054 05059 05060 05063 05115 05061 05280 05062 07665 06900 05064 05283 06667 13286 05281 05116 05065 05275 05066 06996 05067 07723 Part List GP8050 GP8060 GP8065 Description Crankcase Oil Filler Plug Assy with Vent Oil Dipstick Assy O Ring Plug G1 2 Seal Bearing Cover Closed Bearing Cover Open Radial Shaft Seal O Ring Hexagon Socket Screw Spring Ring Clip Ring Tapered Roller Bearing Tapered Roller Bearing Fitting Disc Fitting Disc Fitting Disc Crankshaft
17. ves together with the 13 Reassemble in reverse order Thread the long crosshead as far as possible into the crosshead guide end of the crankshaft together with the inner Take out bearing cover 14 14A and push out crank bearing rings into the crankcase then mount shaft taking particular care that the con rod doesn t get outer bearing ring 20 and spacer ring 22A bent Check surfaces on the connecting rods 24 Mount connecting rod halves in their exact crankshaft 22 and crossheads 25 Check the original position and tighten at 37 Ft Ibs surfaces of the crosshead guides in the crankcase for Connecting rods must be able to any unevenness move slightly sideways on the stroke journals 14 Mount bearing cover 14A and tighten screws 17 to 64 Ft lbs Adjust axial play clearance on the crankshaft to minimum 0 1 mm max 0 15 mm using shims 21A 21B The shaft should turn easily with little clearance Connecting rod must sit exactly in the middle of each crank pin Fit the bearing cover 14 and tighten the screws 17 at 64 Ft lbs Seal 32A must always be installed so that the seal lip on the inside diameter faces the oil Possible axial float of the seal adaptor 33 to be compensated with shims 33C 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 11
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