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2

20 minutes an hour, with the pump running with-out 

pressure or turned off in between. For example, this 

can be full load operation for 5 minutes four times an 

hour with 10 minute breaks in between or continuous 

full load operation for 20 minutes followed by a 40 

minute break.

IMPORTANT!  If higher medium temperatures or 

liquids other than water are involved or aggressive 

media such as seawater, demineralised water etc., the 

pump must be fitted with a separate cooling circuit. 

The separate cooler must have a cooling efficiency of 

1700 watt. If there is a danger of frost, an appropriate 

amount of antifreeze must be mixed into the cooling 

circuit.
When starting up for work, the pump must run first at 

zero pressure for approximately 1 minute.

IMPORTANT!  The GP8100 series has a black arrow 

on the reduction gear which shows the preferred 

direction of rotation. The pumps can be de-livered 

either with the gear on the left side or right side which 

eases the planning of assembling units with regard to 

rotational direction.

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 connecting rods correctly shovels the 

oil on to the crosshead guides – which is a particular 

advantage where continuous operation is involved.

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 

in this direction to smoothen the 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 

maximum operating pressure; the pump is then run in. 

Check the oil temperature during this process.

IMPORTANT!  The pump and cooling system must be 

emptied if there is a danger of frost. Travel wind 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 L-joints (K11) 

on the pump head (50). Blow out the circuit liquid at 

the joint connection (K11/K7) using compressed air.
The torque tenson on the valve casing nuts (49A) is to 

be checked after approximately 200 operating hours. 

Please see the section ‘Maintenance’ concerning the 

torque values.

The pump must be at zero pressure when checking 

the torque tension.

IMPORTANT!  The service life of the seals is 

maximized if a minimal amount of leckage 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 leckage 

become excessive (=constant dripping).

INSTALLATION INSTRUCTIONS

The stated figures are for maximum pressure 

and maximum speed (rpm) and apply for interval 

operation with cold water.
Required NPSH refers to water (specific weight 1kg/

dm3, viscosity 1°E) at maximum permissible pump 

revolutions.
Fluid medium: Clean water filtered with 200μm.

*higher temperatures possible with separate 

crankcase cooling system; the manufacturer is to be 

contacted in this case.

Operation and Maintenance

Check oil level prior to starting and ensure trouble-

free water supply.

IMPORTANT!  If there is a 

danger of frost

the water in the pump and in the pump fittings 

(particularly the unloader valve) must be emptied. 

The second discharge port can also be used and the 

pump run “dry” for 1-2 minutes for this purpose.

Oil amount:

 4.2 gallons (16.0 litres). Only use 

ISO 

VG 220 industrial gear oil

 (e.g. Aral Degol BG220) 

or 

automobile gear oil SAE 90 GL4

. Initial change 

after 50 operating hours and then every 1000 

operating hours after one year latest.

IMPORTANT!  When operating in damp places 

or with high temperature fluctuations. Oil must be 

changed immediately should condensate (frothy oil) 

occur in the gear box.

NPSH values must be observed.
Cooling the Gear Oil

IMPORTANT!  The water input pressure must not 

exceed 29 PSI (2 bar) when using the integrated 

system for cooling the gear oil (standard version). 

If a 

separate

 cooling circuit (maximum 29 PSI [2 

bar]) is installed, it is then possible to have an input 

pressure of up to maximum 145 PSI (10 bar) on the 

suction side

 of the pump.

Make sure that suction pulsation is sufficiently 

dampened – water column resonance must be 

avoided.

IMPORTANT!  The pumps can be run without gear 

oil cooling in continuous operation 

up to

 a power 

rating of 

93.9 HP (70 kW)

 or with major intermit-tent 

operation at full performance.

If operational power 

exceeds 93.9 HP (70 kW)

 or if 

continuous operation is the case, the pump must be 

run with the integrated oil cooling system. The max. 

temperature of the water being pumped and which is 

also fed through the cooling system must not exceed 

86 °F (30 °C). The water amount which is fed into 

the cooling system depends on the pump speed and 

is approximately 1.9 GPM (7.0 L/min) at 580 pump 

rpm. The cooling water is sucked in by one of the 

pumping chambers and pumped away.

Definition of intermittent operation:

 operation 

at full performance for not more than altogether 

Summary of Contents for GEARBOX Series

Page 1: ...7 Repair Instructions pages 8 10 Troubleshooting Chart page 11 Torque Specifications page 11 Dimensions back page Warranty Information back page Triplex Ceramic Plunger Pump Operating Instructions Repair and Service Manual Series GP8155 1000 GP8160 1000 GP8165 1000 GEARBOX SERIES GP8100 Spheroidal Nickel Plated Cast Iron Manifold GP8100 1000 Bronze Manifold Updated 03 22 ...

Page 2: ...MPORTANT The service life of the seals is maximized if a minimal amount of leckage 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 leckage become excessive constant dripping INSTALLATION INSTRUCTIONS The stated figures are for maximum pressure and maximum speed rpm and apply for interval operation...

Page 3: ...y maintenance work to the pump or unit Close off suction line Disconnect fuses to ensure that the driving motor cannot get switched on accidently Make sure that the pump the cooling system and all parts on the pressure side of the unit are vented and refilled with pressure at zero before starting the pump In order to prevent air or an air water mixture being absorbed and cavi tation occurring the ...

Page 4: ...t of head GP8155 75 5 3000 580 145 2 17 23 GP8160 90 2500 580 147 2 36 23 6 GP8165 105 6 120 2000 580 658 142 166 2 55 26 2 Max Flow Maximum Pressure Maximum Speed Power Required Plunger Diameter NPSHR Model L min Bar RPM kW mm mWs GP8155 285 200 580 108 55 7 0 GP8160 337 170 580 110 60 7 2 GP8165 400 455 140 580 658 106 123 65 8 0 U S Measurements Metric Measurements U S Metric Maxiumum Inlet Pre...

Page 5: ...65 09586 Item Part Description Qty 38A 06667 O Ring 6 39A 05066 O Ring 3 40 06996 Seal Ring 3 42 06997 V Sleeve 9 Inlet Valve Kit 09587 Item Part Description Qty 51B 05078 Inlet Valve Seat 1 51C 05079 Valve Plate 1 51D 07658 O Ring 1 51E 05080 Valve Spring 1 56A 06258 O Ring 1 Discharge Valve Kit 09588 Item Part Description Qty 52B 05084 Discharge Valve Seat 1 52C 05079 Valve Plate 1 52D 06258 O R...

Page 6: ...6 Exploded View GP8155 GP8160 GP8165 ...

Page 7: ...leeve Support Ring GP8155 3 43 05070 Sleeve Support Ring GP8160 3 43 05118 Sleeve Support Ring GP8165 3 Item Part Description Qty 45 05279 Seal Tension Spring GP8155 3 45 05071 Seal Tension Spring GP8160 3 45 05119 Seal Tension Spring GP8165 3 49 05072 Stud Bolt 8 49A 05073 Hexagon Nut 8 50 05074 Valve Casing GP8155 GP8160 GP8165 1 50 05074 3000 Valve Casing 1000 Versions 1 50A 13162 Centering Stu...

Page 8: ... 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 seat ing Replace pressure spring 57A and...

Page 9: ...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 ten sion 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 tensio...

Page 10: ...onger be turned by hand Then remove a shim and establish whether the crankshaft can now be turned A crankshaft that can be too easily turned may cause damage to the bearings 20 21 and connecting rods 24 due to the wobble movements in the conical bearing shells If bearings 20 21 have been replaced the flange 19 must be taken off and a new bearing outer ring pressed in until the surfaces are even Th...

Page 11: ... Shaft seal ring leaks Check seal and shaft 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 Troubleshooting GP8155 GP8355 GP8160 GP8360 GP8165 GP8365 TOOL LIST AND TORQUE SPECIFICATIONS Item P...

Page 12: ... or modifications made by the customer or third party 6 Theoperationofpumpsandoraccessoriesexceedingthespecificationssetforth 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 f...

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