2
INSTALLATION INSTRUCTIONS
Operation and Maintenance
Check oil level prior to starting and ensure trouble-free
water supply.
Oil:
Use only 1.7 gallons (6.3 liters) of ISO VG-220
synthetic gear oil. Initial change after 50 hours and then
after every 200 operating hours. If used less than this,
change once per year.
IMPORTANT!
When operating in humid areas (or areas
with large temperature fluctuations, the oil must be
changed immediately (if condensate or frothy oil occurs
in the crankcase).
I
MPORTANT!
We recommend that both inlet ports be
used in order to ensure cavitation-free operation and op-
timal suction conditions. If only one connection is use, a
safety margin of 3 feet (1 meter) has to be added to the
required NPSH.
IMPORTANT!
If the pump is mounted on a vehicle with
the possibility of unlevelness and/or the pump speed is
between 300 & 500 RPM, the volume of oil should be
1.93 gallons (7.3 liters). To check, put the oil dipstick in
the bore situated next to the eye bolt.
IMPORTANT!
The GP7636GBHS-2.4 pumps has a
black arrow on the reduction gear, which shows the pre
-
ferred direction of rotation. The pump can be delivered
either with the gear on the left side or right side (when
facing the front of the pump), which eases planning
assembled units with regard to the desired direction or
rotation.
In either case, the larger gear wheel must
rotate towards the front-end of the pump.
The preferred/optimal direction of rotation ensures that
the oil is correctly splashed on the crosshead guides via
the motion of the connecting rods, which is a particular
advantage where continuous operation is involved.
The pump can also be run against the recommended
direction of the rotation if operated periodically or at re-
duced pressure. If this is the case, the pump has to be
run 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. This should run-in the pump, but
you should also check the oil temperature, which should
not exceed 140
o
F (60
o
C).
The torque tension on the valve casing nuts (49A) is to be
checked after approximately 200 hours. Please see page
7 for torque values.
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 examine every day. If the leakage becomes
excessive (constant dripping), the plunger seals must be
changed.
Safety Rules
The operating instructions must be read and adhered
to before performing any work on the pump or com-
plete assembled unit. No responsibility will be carried
by us for damage to materials or persons caused by
improper handling of our pumps
.
Access to the pump is not allowed by unauthorized person-
nel. As safety valve is to be installed in accordance with
the guidelines for liquid spraying units, so that the admis
-
sible operating pressure cannot be exceeded by more than
10%. Pumps operating without a safety valve as well as
any excess in temperature or speed limits automatically
voids the warranty. When the pump is in operating, the
exposed shaft side, the driven shaft side and its coupling
must be covered by a protective guard. The plunger area
must also be covered by the protective plate (30). Do not
step onto the protective plate (30 ) or put weight on it.
Before carrying out any maintenance work to the pump or
pump unit, the pressure in the discharge line and pump
must be at zero. Close off the suction line. Disconnect
fuses to ensure that the driving motor cannot accidently
get switched on. Before starting the pump, 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.
In order to prevent air or air/water-mixture being absorbed
and cavitation occurring, the pump NPSHR (Net Positive
Suction Head Required) and water temperature must be
adhered to.
Cavitation and/or compression of gases lead to uncon-
trollable pressure kicks, which can ruin the pump and
unit parts and also be dangerous to the operator or
anyone standing nearby.
Giant plunger pumps are only suitable for pumping fresh
clean water.
