Giant GP8155-R User's Manual
Contents
1. M O D B Triplex Ceramic Plunger Pump Model Manual GIANT INDUSTRIES LIMITED WARRANTY G P81 55 R Giant Industries Inc pumps and accessories are warranted by the manufacturer to be free from defects in orkmanship and material as follows O 1 For portable occur ma and self service car wash applications the discharge manifolds will never WITH INTEG RAL G EARBOX 1 80 REVERSE 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 One 1 year from the date of shipment for all other Giant industrial and consumer pumps Six 6 months from the date of shipment for all rebuilt pumps 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 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 o2. Up to 80 P nsss 30 C IMIE CPOS onesna a 2 3 BSP Decbr cal POS r O EO 2 1 1 4 BSP Me PD eni 794 MDS Seccanebsseteaceess 360kg Crankcase Oil Capacity secssunincsccevsisiorcasssasaisenes Fa eE 14 0 liters Fluid End Material cccccccccceceeeeeeeeeeenees 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 GP8155 R HORSEPOWER The rating shown are the power REQUIREMENTS requirements for the pump Gas engine power ups mus be 51 6 17 i 71 We recommend a 1 15 service factor be specified when selecting an electric motor as the power source To compute specific pump SPECIAL NOTE horsepower requirements use the The theoretical gallons per revolution gal rev is 0 129 following formula To find specific outputs at various RPM use the formula GPM X PSI _ HP GPM 0 129 x RPM 1450 EXPLODED VIEW GP8155 R amp K15 amp Kii GP8155 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 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 screw
3. 05036 05037 05038 05039 05124 05416 05417 05042 05043 05113 05418 05419 05047 05048 05049 05051 07408 05420 05421 05422 05052 07225 0100 13136 08280 05050 07623 05058 05055 05056 05054 05059 05060 05280 05062 07665 06900 05283 13286 05281 05275 05066 07723 05276 05277 05278 05279 05072 05073 05074 Parts List GP8155 R Description Crankcase Oil Filler Plug Assy with Vent 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 1 5 O Ring Plug G3 8 Copper Washer Bearing Cover Closed O Ring Hexagon Socket Screw M12 Spring Ring Clip Ring Tapered Roller Bearing Tapered Roller Bearing Fitting Disc Fitting Disc Fitting Disc Crankshaft For Turned Gear Fitting Key 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 Cover Plate Hexagon Screw Grommet Washer Splash Cover Eye Bolt Radial Shaft Seal Seal Retainer O Ring Clip Ring Fitting Disc Oil Shield Plunger Pipe Tension Screw Copper Washer Centering Sleeve Seal Case O Ring Support Ring Seal Sleeve O Ring Compact Ring Pressure Ring Sleeve Sleeve Support Ring Seal Tension Spring Stud Bolt Hexagon Nut Valve Casing Qty CO CO WW OO WD WW WD DW W W W W W WW WW WW Bre OO WNP RK NON ND DW W W WR
4. FR WW WR RR CO COR RR BWR RR Re ke BB BN NY RR Item SOA 50B 51 S1A SIB SIC 51D SIE S1F 52 52A 52B 52C 52D 52E 532F 56 56A 57 57A 58 59 59A 60 61 62 62A 66 67 67A 68 69 70 T2 73 74 75 75A 76 77 78 79 80 81 K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 K12 K13 K14 K15 K16 Part 13162 05075 05076 05077 05078 05079 07658 05080 05081 05082 05077 05084 05079 06258 05080 05081 05085 06258 05086 07210 0100 05087 07109 06272 06909 05088 05302 06934 05423 05424 07274 05425 05426 07614 05427 05428 05429 05430 05431 05432 05433 05025 07662 07544 05434 05026 05027 05028 05029 07381 08041 05030 06272 07109 05120 05032 05033 05402 05435 05404 05436 Description 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 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 Gear Cover Hexagon Screw Washer Cylinder Pin Gear Wheel Set 2200 RPM 3 8 Fitting Key Hexagon Screw Shaft Seal Ring for Gear Roller Bearing Roller Bearing Fitting Disc Gear Seal Flange c w Gear Oil Cooler Mounting Aid for Valve Hexagon Socket Screw
5. 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 G1 2 Connecting Branch U Joint Connector c w Nut Tube for Cooler Hose Clamp Hose Guard Hose Coupling Nut Flat Gasket Qty GP8155 R PUMP REPAIR INSTRUCTIONS GP8155 R PUMP REPAIR KITS Valve Ins ection and Re air Plunger Packing Kit 09616 Inlet Valve Kit 09587 Item Part Description Qty Item Part Description Qty AE ae a E e 38A 13286 O Ring 6 51B 05078 Inlet Valve Seat 1 1 mt 39A 05066 O Ring 6 51C 05079 Valve Plate 1 40 07723 Seal Ring 3 51D 07658 O Ring 1 i 42 05277 V Sleeve 9 SIE 05080 Valve Spring 1 SIF 05081 Valve Spring Guide 1 56A 06258 O Ring 3 Oil Seal Kit 09584 Discharge Valve Kit 09588 Item Part Description Qty Item Part Description Qty 32 05058 Radial Shaft Seal 3 52B 05084 Discharge Valve Seat 1 1 Remove socket head cap 2 Lift discharge casing 3 Take out pressure springs 33A 05056 O Ring 3 52C 050 9 Valve Plate I screws 58 50B up and away 57A Pull out assembled S2D 56A 06258 O Ring 2 valves 51 amp 52 with valve puller 5ZE 05080 Valve Spring 1 52F 05081 Valve Spring Guide 1 GP8155 R TOOL LIST AND TORQUE SPECIFICATIONS Part Description Torque Ft Lbs Tool Needed Hexagon Socket Screw Connecting Rod Hex Hd Socket Screw Clip Ring Tension Screw 9A 05073 Hexagon Nut Mani
6. 9 PSI the inlet pressure can be amaximum of 145 PSI To empty the cooling circuit remove the L joints K11 on the pump head 50 Blow out the circuit liquid at the joint connection K11 K7 using compressed air The torque tension on the valve casing nuts 49A should be checked after approximately 200 operating hours Please see page 7 for torque values GP8155 R DIMENSIONS mm 922 _ 229 ee O __ ee a o o S are Diha Pie te 2 G 11M l ley pl el Hri ial o kin Tf ia ee ee I 4xM12 ata S11 3 64 Bi J32 rE 189 Il GP8155 R PUMP REPAIR INSTRUCTIONS 15 Replace seal retainer 33 seal 32 and clip ring 33B Seal 82 must always be installed so the seal lip on the inside diameter faces the oil Possible axial float of the seal retainer 33 to be compensated with shims 33C Re assemble the seal sleeves 39 and plunger pipes 36B Tighten the tension screw 36C to 30 Ft lbs Replace valve casing and tighten hexagon 16 Mount cooling plate K1 and gear cover K3 with their respective seals K2 When assembling the cooling circuit line make sure that the oil cooler connection K7 is always joined to the upper connection K3 of the gear cover Heat ball bearings 74 and 75 first before pressing them on to the pinion Press the cogwheel slightly on to the crankshaft so that the pinion 69 together with the ebaring 74 can be inserted Move the pinion 69 against the c
7. e 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 tions invalidates the warranty 1 Prior to initial operation add oil to crankcase so that oil level is between the two lines on the oil dipstick DO NOT OVERFILL Use Industrial synthetic gear lube oil ISO VG 220 such as Mobil Gear 630 Shell Omala oil 220 or Texaco Meropa 220 Crankcase oil should be changed after the first 50 hours of operation then at regular intervals of 200 hours or less depending on operating conditions Run pump for one 1 min at ZERO PSI before operating under pressure 2 Pump operation must not exceed rated pressure volume or RPM A pressure relief device must be installed in the discharge of the system 3 Acids alkalines or abrasive fluids cannot be pumped unless approval in writing is obtained before operation from Giant Industries Inc Pump fluid should be filtered to 300 micron 5 Crankshaft rotation on Giant Industries Inc pumps should be made in the direction designated by the arrows on the pump crankcase Reverse rotation may be safely achieved by following a few guidelines available upon reques
8. fold 265 360 30mm Socket 1 54 05076 05082 Valve Assemblies N A Valve Puller p n 07662 Included w pump 05087 Hexagon Socket Screw 13280 ____ 12mm Allen Wrench 07381 Hexagon Socket Screw 8mm Allen Wrench GP8155 R TROUBLESHOOTING I UD ww 4 Remove valve assembly 52 from discharge valve adapter 56 by gently twisting apart The spring tension cap 51A 52A is screwed together with the valve seat 51B or 52B Screw off spring tension cap Takeout springs 51E 52E and valve plate 51C 52C Check sealing surfaces and O rings 51D 52D Replace worn parts Coat threads of valve seat with silicon grease or molycote anti seize Cu 7439 when reassembling Before refitting the valves clean the sealing surfaces in the casing and check for any damage Coat o rings 51D 52D amp 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 133 Ft lbs check torque tension after 8 10 operating hours 6 51 58 K5 pd Oo NO pd CO Problem n aeee To Check Seals and Plunger Pipe plunger Pressure drops pump gets loud Discharge or suction val
9. m 0 15mm using shims 21A B Connecting rods must sit exactly in the middle of the crankshaft journal Mount connecting rod halves in the exact original position and tighten to 37 Ft lbs The shaft should turn easily important Connecting rods must be able to move slightly sideways on the stroke journals GP8155 R PUMP REPAIR INSTRUCTIONS 7 Importa nt 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 Insert 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 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 Importa nt 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 pres sure and valve casing 9 Coat the seal sleeve 39 lightly with a
10. nti corrosive grease e g molycote no Cu 74339 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 Importa nt 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 10 Put seal cases 38 in the centering holes of the valve casing then push valve casing carefully on to centering studs 50A Tighten hexagon screws 49A evenly and crosswise at 266 Ft Ibs Importa nt 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 o aN NNBWN Fe 21C 29A 29B 29C 29D 30 30A 30B 30C 30D 31 32 33 33A 33B 33C 34 36B 36C 36D 36E 38 38A 38B 39 39A 40 Al 42 43 45 49 49A 50 Part 05410 06893 05411 05412 05413 05414 05381 05035 01009 05415 07102 06273 22929
11. ogwheel 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 important 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 10 Specifications Model GP8155 R U S Metric NOLO aare E A Up to 74 8 GPM 283 LPM Discharge Pressure so sccssscncssrtswsncersnsbietieesverionss Up to 2900 PSI 200 bar SPEO ee Up to 580 RPM 580 RPM le Pres U ea sraresearccsaaanatndescevavsanevuanonsvareeaarere Upto 29 PSM vias 2 0 bar Plunger Diameter c ccesessesesseeeeeeeeeeeees DN siemetedungunsdaneweuss 55mm Plonger Obl OK Cen snatee pisces tre rsouduicshedetetiantind DOD A E 72mm Crankshaft Diameter c c sseeeeeeeeeeeeeeees L E 70mm E E a PEEN EE EA AEA OII aen 14mm Crankshaft Mounting cccccsssssseeceecececeeeeeeeeeeeaaaeeeeaeaaeeseeeeeeseees Either side ARO aO e E E Top of pulley E tocaiseuaiateseasdeecseaeaeasas seanesscoseed ae yeeeeete cece sen esse cveeeeeneases Towards manifold Temperature of Pumped Fluids 0000000000000
12. r 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 THELIMITED WARRANTY SET FORTH HEREIN ISIN LIEU OF ALLOTHER WARRANTIES OR REPRESENTATION EXPRESS OR IMPLIED INCLUDING WITHOUT LIMITATION ANY WARRANTIES OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE AND ALL SUCH WARRANTIES ARE HEREBY DISCLAIMED AND EXCLUDED BY THE MANUFACTURER Contents GIANT INDUSTRIES INC 300 N Westwood Ave Installation Instructions page 2 Toledo Ohio 43607 Pump Specifications page 3 419 531 4600 e FAX 419 531 6836 Exploded View Parts List a pages 4 5 www giantpumps com Repair Kits Tool List To
13. rque Specifications page 6 Troubleshooting Chart page 6 Repair Instructions pages 10 Dimensions page 11 Copyright 2008 Giant Industries Inc 4 08 GP8155 R PMD Updated 4 08 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 these pumps are to be operated at temperatures in excess of 86 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 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 Th
14. s K4 12 Remove the connecting rod screws 24 Important 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 out of the crankcase by gently tapping it with a rubber mallet Remove connect ing rod 24 and crosshead 25 from crankcase Remember that this assembly must be re assembled exactly as it was removed Check surfaces on connect ing rods 24 crankshaft 22 and crosshead 25 Check the surfaces of the crosshead guides in the crankcase for any uneveness 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 210 Snap in the clip ring 19 and insert crankshaft from other side then press in the roller bearing 20 Mount bearing cover 14 and tighten screws 17 to 64 Ft lbs Adjust axial play clearance on the crankshaft to minimum 0 1m
15. t from Giant Industries Inc Required horsepower for system operation can be obtained from the charts on page 3 6 Before beginning operation of your pumping system remember Check that the crankcase and seal areas have been properly lubricated per 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 Importa nt 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 Finally remember that high pressure operation in 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 3 Importa nt 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 1s above freezing point 6 Inlet pressure not to exceed 29 PSI when using the integrated oil cooling system If using a separate cooling system max 2
16. ve leaks Replace valve s x SS ee Steam formation Cavitation Reduce suction height reduce flow resistance in inlet line clean inlet filter lower water temperature irregular pressure O ring on valves or inlet valve adapter leaks Examine O rings check valve pny DIHEN casing for unevenness on the sealing surfaces Oil leaks at visible part of plungey Gear sealing is leaking Examine seals and running surface of plunger Dirty milk colored or frothy oil Water has mixed with oil Replace oil immediately find amp fix 5 Remove hexagon nuts 49A and valve 6 Remove tension screw 36C and take the cause casing together with seal case 38 from seal sleeve 39 together with all mounted Oil leakage on the crankshaft Shaft seal ring leaks Check seal and shaft Sy AnCaS en NECES A CEU tape parts out of the drive Pull plunger pipe 36B Noise increases without the loss Worn bearing 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 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 out of the seal assembly and check for any damage Carefully remove seal rings 40 and sleeves 42 with a screwdriver
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