Triplex Ceramic
Plunger Pump
Models Manual
Models
GP8045 / GP8048
Contents:
Installation Instructions:
Pump Specifications (GP8045):
Exploded View
Parts List:
page 2
page 3
page 4
page 5
page 6
Pump Specifications (GP8048):
Repair Kits/Tool List:/Torque Specifications
Troubleshooting Chart:
Repair Instructions:
Dimensions:
WarrantyInformation
page 7
page 7
pages 8-10
page 11
back page
Download from Www.Somanuals.com. All Manuals Search And Download.
Specifications
Model GP8045
U.S.
(Metric)
Volume .............................................................Up to 48.9 GPM ...... (185 LPM)
Discharge Pressure .........................................Up to 4350 PSI ........ (300 bar)
Speed ...............................................................Up to 580 RPM ....... 580 RPM
Inlet Pressure...................................................Up to 29 PSI............ (2.0 bar)
Plunger Diameter............................................. 1.77” ........................ 45mm
Plunger Stroke .................................................2.83” ........................ 72mm
Crankshaft Diameter........................................2.76” ........................ 70mm
Key Width........................................................ 0.55” ........................ 14mm
Crankshaft Mounting......................................................................... Either side
Shaft Rotation .................................................................................... Top of pulley towards manifold
o
Temperature of Pumped Fluids........................Up to 86 oF .............. (30 C)
Inlet Ports .......................................................................................... (2) 3” BSP
Discharge Ports ................................................................................. (2) 1-1/4” BSP
Weight ..............................................................705 lbs. .................... (320kg)
Crankcase Oil Capacity ...................................3.3 Gal. .................... (12.5 liters)
Fluid End Material............................................ 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:
The rating shown are the power
GP8045 HORSEPOWER
requirements for the pump. Gas
REQUIREMENTS
engine power outputs must be
RPM GPM 1000 PSI 2000 PSI 3000 PSI 4350 PSI
approximately twice the pump
power requirements shown above.
300 25.3
400 33.7
500 42.2
580 48.9
17.4
23.2
29.1
33.7
34.9
46.5
58.2
67.5
52.3
69.7
87.3
75.9
101.1
126.6
146.7
We recommend a 1.15 service
factor be specified when selecting
an electric motor as the power
source. To compute specific pump
horse power requirements, use the
following formula:
101.2
SPECIAL NOTE:
The theoretical gallons per revolution (gal/rev) is 0.0843.
To find specific outputs at various RPM, use the formula:
GPM X PSI
= HP
1450
GPM = 0.0843 x RPM
3
Download from Www.Somanuals.com. All Manuals Search And Download.
EXPLODED VIEW -- GP8045 / GP8048
Download from Www.Somanuals.com. All Manuals Search And Download.
Item
1
2
5
6
7
8
9
12
13
14
14A
15
16
17
18
21
21A
21B
22
23
24
25
28
29
29A
29B
30
30A
30B
30C
30D
31
Part
Description
Crankcase
Qty
1
1
2
1
1
1
1
2
2
1
1
1
Item
43
45
45
49
49A
50
50A
50B
51
51A
51B
51C
51D
51E
51F
52
52A
52B
52C
52D
52E
52F
56
56A
57
58
59
59A
60
Part
Description
Qty
3
3
3
8
8
1
2
1
3
3
3
3
3
3
3
3
3
3
3
6
3
3
3
3
6
12
2
2
1
1
6
6
1
1
1
1
05380
06893
22929
06273
05381
05035
01009
07109
06272
05036
05298
05112
05037
05038
05039
05044
05042
05043
05299
05300
05047
05048
05049
05051
05382
05383
05052
05396
05279
07636
05072
05073
05397
13162
05398
05399
08281
05400
05314
05401
Support Ring (GP8045)
Pressure Ring (GP8048)
Pressure Ring (GP8045)
Stud Bolt
Hexagon Nut
Valve Casing
Oil Filler Plug Assy
Copper Washer
Oil Drain Plug
Plug, Oil Dip Stick
Oil Dip Stick Ass’y
O-Ring
Centering Stud
Plug G-1/2
Copper Ring
Discharge Casing
Suction Valve Ass’y
Spring Tension Cap
Suction Valve Seat
Valve Plate
Bearing Cover Closed
Bearing Cover Open
Radial Shaft Seal
O-ring
Inner Hexagon Screw
Spring Ring
Tapered Roller Bearing
Fitting Disc
Fitting Disc
2
O-Ring
16
16
2
1-5
1-5
1
1
3
3
3
4
2
2
1
5
5
9
1
3
3
3
3
3
3
3
3
3
3
3
3
6
3
3
3
07732-0100 Valve Spring
08282
05406
08281
05407
05314
05408
Valve Spring Guide
Discharge Valve Ass’y.
Spring Tension Cap
Discharge Valve Seat
Valve Plate
Crankshaft
Fitting Key
O-Ring
Conn-rod Assy
Crosshead c/w Plunger
Crosshead Pin
Hexagon Screw
Bracket 1 - Cooling Hose
Bracket 2 - Cooling Hose
Cover Plate
07732-0100 Valve Spring
08282
05409
05408
07173
05087
07109
06272
06909
05088
05302
06934
05303
13433
05052
07662
Valve Spring Guide
Discharge Valve Adapter
O-Ring
Tension Spring
Hexagon Socket Screw
Plug G-1/2
Copper Gasket
Plug G 1-1/4
Plug G-3
Plug G-1/4
Copper Gasket
Disc for Crankshaft
Hexagon Screw
Oil Cooler
07225-0100 Screw 316 S.S
13136
08280
05050
07623
05058
05056
05054
05059
05060
05384
05385
05062
07665
06900
05386
05387
05388
05389
05066
05390
13290
05391
05392
05393
05394
05395
Grommet
Washer
Splash Cover
Eye Bolt
Radial Shaft Seal
O-Ring
Clip Ring
Fitting Disc
Oil Shield
Plunger Pipe (GP8048)
Plunger Pipe (GP8045)
Tension Screw
Copper Washer
Centering Sleeve
Seal Case
61
62
62A
66
67
32
33A
33B
33C
34
36B
36B
36C
36D
36E
38
38A
39
39
39A
40
40
78
79
Tool for Valve
K1
K2
K3
K4
05026
05027
05028
05029
Cooling Vane Plate
Seal for Gear Cover
Gear Cover
Hexagon Head Countersunk
Screw
Hexagon Socket Screw
Washer
Connection for Oil Cooler
Copper Seal
1
2
1
8
8
8
1
6
2
3
3
2
4
2
1
4
K5
K6
K7
K8
07381
08041
05030
06272
07109
05031
05032
05033
05402
05403
05404
05405
O-Ring
Seal Case (GP8048)
Seal Case (GP8045)
O-Ring
Seal Ring (GP8048)
Seal Ring (GP8045)
Pressure Ring (GP8048)
Pressure Ring (GP8045)
Sleeve (GP8048)
Sleeve (GP8045)
Support Ring (GP8048)
K9
Plug G1/2
3
3
3
3
9
9
3
K10
K11
K12
K13
K14
K15
K16
Connecting Branch
U-Joint Connector w/Nut
Tube for Cooler
Hose Clamp
Hose Guard
Hose Coupling Nut
Flat Gasket for Oil Cooler
41
41
42
42
43
Download from Www.Somanuals.com. All Manuals Search And Download.
Specifications
Model GP8048
U.S.
(Metric)
Volume .............................................................Up to 56.8 GPM ...... (215 LPM)
Discharge Pressure .........................................Up to 3770 PSI ........ (260 bar)
Speed ...............................................................Up to 580 RPM ....... 580 RPM
Inlet Pressure...................................................Up to 29 PSI............ (2.0 bar)
Plunger Diameter.............................................1.89” ........................ 48mm
Plunger Stroke .................................................2.83” ........................ 72mm
Crankshaft Diameter........................................2.76” ........................ 70mm
Key Width........................................................0.55” ........................ 14mm
Crankshaft Mounting......................................................................... Either side
Shaft Rotation .................................................................................... Top of pulley towards manifold
o
Temperature of Pumped Fluids........................Up to 86 oF .............. (30 C)
Inlet Ports .......................................................................................... (2) 3” BSP
Discharge Ports ................................................................................. (2) 1-1/4” BSP
Weight ..............................................................705 lbs./ ................... (320kg)
Crankcase Oil Capacity ...................................3.3 Gal. .................... (12.5 liters)
Fluid End Material............................................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:
The rating shown are the power
requirements for the pump. Gas
engine power outputs must be
approximately twice the pump
power requirements shown above.
GP8048 HORSEPOWER
REQUIREMENTS
RPM GPM 1000 PSI 2000 PSI 3000 PSI 3770 PSI
300 29.4
400 39.2
500 49.0
580 56.8
20.3
27.0
33.8
39.2
40.6
54.1
67.6
78.3
60.8
81.1
101.4
117.5
76.4
101.9
127.4
147.7
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
= HP
1450
SPECIAL NOTE:
The theoretical gallons per revolution (gal/rev) is 0.0979.
To find specific outputs at various RPM, use the formula:
GPM = 0.0979 x RPM
6
Download from Www.Somanuals.com. All Manuals Search And Download.
GP8045/GP8048 PUMP REPAIR KITS
Plunger Packing Kits
GP8045 - #09626
Valve Assembly Kit - GP8045 & GP8048
Inlet Valve Kit - #09628
Item
38A
39A
40
Part #
Description
Qty.
Item
51B
51C
51D
51E
51F
56A
Part #
05400
05314
05401
Description
Inlet Valve Seat
Valve Plate
O-Ring
Qty.
3
3
3
3
05387 O-Ring
05066 O-Ring
13290 Seal Ring
05394 V-Sleeve
6
3
3
9
42
07732-0100 Valve Spring
08282
05410
Valve Spring Guide
O-Ring
3
3
GP8048 - #09627
Item
38A
39A
40
Part #
Description
Qty.
05387 O-Ring
05066 O-Ring
05390 Seal Ring
05393 V-Sleeve
6
3
3
9
Discharge Valve Kit - #09629
Item
52B
52C
52D
52E
52F
56A
Part #
05407
05314
05408
Description
Qty.
Discharge Valve Seat 3
Valve Plate
O-Ring
42
3
3
3
3
3
Oil Seal Kit - #09584
07732-0100 Valve Spring
08282
05410
Item
32
33A
Part #
Description
Qty.
3
3
Valve Spring Guide
O-Ring
05058 Radial Shaft Seal
05056 O-Ring
GP8045/GP8048 TOOL LIST AND TORQUE SPECIFICATIONS
ITEM
17
24
33B
36C
49A
PART #
05038
05047
05054
05062
05073
DESCRIPTION
TORQUE Ft-lbs (NM) TOOL NEEDED
Hexagon Socket Screw
Connecting Rod Hexagon Socket Screw
Clip Ring
Tension Screw
Hexagon Nut (manifold)
64 (87)
37 (50)
n/a
30 (40)
265 (360)
n/a
10mm allen wrench
8mm allen wrench
Industrial Snap ring pliers
16mm socket
30mm socket
Valve puller (p/n 07662) - included w/ pump
12mm allen wrench
51/52 05399 / 05406 Valve Assemblies
58
K5
05087
07381
Hexagon Socket Screw
Hexagon Socket Screw
132 (180)
n/a
8mm allen wrench
GP8000 Trouble Shooting
Problem
Pressure drops, water leaks
Cause
V-sleeves leak
Solution
Replace V-sleeves, examine surface of
plunger
Discharge or suction valve leaks Replace valve
Pressure drops, pump
becomes loud
Steam formation (cavitation)
Worn valves
Reduce suction height, reduce flow resistance
in inlet line, clean inlet filter, lower water
temperature
Examine valves
Irregular pressure
O-Ring on the valves or inlet valve Examine O-ring, examine valve casing for
adapter leaks
unevenness on the sealing surfaces
Oil leaks at visible part of
plunger
Gear sealing is leaky
Examine seals and running surface of plunger
Dirty mile-colored frothy oil
Oil has mixed with water
Replace oil immediately, find and fix the cause
Oil leakage on the crankshaft
Shaft seal ring leaks
Check seal and shaft
Noise increases without loss of Worn bearing
pressure
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
7
Download from Www.Somanuals.com. All Manuals Search And Download.
GP8045/GP8048 PUMP REPAIR INSTRUCTIONS
Valve Inspection and Repair
1) Remove bolts (58).
2) Remove discharge
casing (50B) up and away.
3) Take out pressure springs
(57A). Pull out assembled
valves (51 & 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)
using a rubber hammer.
IMPORTANT! If necessary, support
the valve casing by resting it on
wooden blocks or by using a pulley.
6) Remove tension screw (36C) and take
seal sleeve (39) together with all mounted
parts out of the drive. Pull plunger pipe out
of the seal assembly and check for any
damage. Carefully, remove seal rings (40)
and sleeves (42) with a screw driver.
8
Download from Www.Somanuals.com. All Manuals Search And Download.
GP8045/GP8048 PUMP REPAIR INSTRUCTIONS
8) Take out the seal case (38) from the valve (if
Be careful not to damage the seal
7)
necessary secure 2 screwdrivers in the front O-ring
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.
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, pres-
sure and valve casing.
Replacing 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.
Tighten the tension screw at 30 Ft-lbs.
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.-lbs.
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.
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).
9
Download from Www.Somanuals.com. All Manuals Search And Download.
GP8045/GP8048 PUMP REPAIR INSTRUCTIONS
To Dismantle Crankcase Gear
10) 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) with a screwdriver. Open hose adaptor (K11) and
remove gear cover (K3). Remove the cooling vane plate
(K1) by removing the screws (K4)
11) Remove the connecting rod screws (24).
Connecting rods are marked 1 to 3
for identification. Do not twist connecting rod
halves or interchange them. When reassembling,
the connecting rod must be fitted in their exact
original position on the crankshaft journals.
12) Push connecting rod halves together with the
crosshead as far as possible into the crosshead guide.
Take out bearing cover (14/14A) and push out crank-
shaft taking particular care that the con rod doesn’t get
bent. Check surfaces on the connecting rods (24),
crankshaft (22) and crossheads (25). Check the
surfaces of the crosshead guides in the crankcase for
any unevenness.
13) Reassemble in reverse order. Thread the long
end of the crankshaft together with the inner
bearing rings into the crankcase; then mount
outer bearing ring (20) and spacer ring (22A).
Mount connecting rod halves in their exact
original position and tighten at 37 Ft-lbs.
Connecting rods must be able to
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.
10
Download from Www.Somanuals.com. All Manuals Search And Download.
Download from Www.Somanuals.com. All Manuals Search And Download.
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:
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.
Liabilityunderthiswarrantyisonallnon-wearpartsandlimitedtothereplacementorrepairofthoseproductsreturned
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, EXPRESSORIMPLIED, INCLUDINGWITHOUTLIMITATIONANYWARRANTIESORMERCHANTABILITY
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
(419) 531-4600
FAX (419) 531-6836
Copyright 2008 Giant Industries, Inc.
3/08 GP8045,GP8048.PMD
Download from Www.Somanuals.com. All Manuals Search And Download.
|