GIANT PUMPS GP8035 Setup guide

7
To Check Valves
Loosen screws (58) and lift discharge casing (50B) up and away. Take out pressure springs
(57). Pull out assembled valves (51 and 52) with fitting tool (p/n 07662).
Dismantling valves: the spring tension cap (51A, 52A) is screwed together with the valve
seat (51B/52B). Remove spring tension cap, take out springs (51E/52E) and valve plate
(51C/52C). Check sealing surfaces and O-rings (51D/F, 52D/F, 56A).
Replace worn parts.
Coat threads of valve seat with silicon grease or molycote anti-seize Cu-7439 when reas-
sembling. Before refitting the valves, clean the sealing surfaces in the casing and check for
any damage.
Tighten screws (58) at 132 Ft-lbs (180 NM); check torque tension after 8-10 operating
hours.
To Check Seals and Plunger Pipe
Screw off hexagon nuts (49A) and hose coupling (K11 and K15). Remove pump head
together with seal case (38) and intermediate casing (62) from crankcase (1). If necessary,
carefully tap the valve casing (50) past the centering stud (50A) using a rubber hammer.
Important! If necessary, support the pump head by resting it on wooden blocks or by using
a pulley.
Take off flat leakage seal (62D) and check.
Remove plunger (36) from crosshead with plunger base (25) and take seal sleeve (39)
together with all mounted parts out of the drive.
Pull plunger out of seal assembly and check for any damage. Clean centering and top-sur-
face of crosshead with plunger base (25). Take out tension spring (45). Carefully remove
the whole seal unit (41-44) by using socket wrench or backside of a screwdriver. Check
plunger surface and seals. Check O-rings (39A).
Renew damaged parts.
After removing off clip-ring (40C) and pressure ring (40B), check leakage seal (40) and O-
ring (40A) and renew (if necessary).
Important! Be careful not to damage seal sleeve (39) pressure ring (41) and guide ring
(41A). Check the inner diameter of the pressure ring and guide ring for wear and if nec-
essary replace together with seals (42) and support ring (44). Clean all parts. New parts
should be lightly coated with silicon grease before installation.
Insert the seal unit (41-45) into the seal sleeve (39). Push the plunger (36) carefully
through the seals from the crankcase side. If necessary, the seals can be held tightly using
a suitable pipe support held on the other side of the seal sleeve.
Take out the seal case (38) from the intermediate casing (62) and check O-rings (38A). If
necessary, secure 2 screwdrivers in the front O-ring groove to extract seal casing from
intermediate casing. Coat O-rings with silicon grease before installing.
Important! Mounting surfaces of the crankcase, seal sleeves, intermediate casing and
Repair Instructions - GP8035 Pump

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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 crank-
case, intermediate casing, pressure-and valve casing.
Coat the seal sleeve lightly with anticorrosive grease (e.g. molycote no. Cu-7439) in its fit-
ted area towards the crankcase. Insert seal sleeves in to their crankcase fittings.
Important! Watch the even milled surfaces on the seal sleeves. They must be positioned
vertically on each other.
Turn the pump (by hand) until the plunger (25) rests against the plunger (36). Tighten
plunger (36) to 33 Ft-lbs. (45 NM).
Insert the seal tension spring (45) in to the seal sleeve (39).
Mounting Valve Casing:
Press seal cases (38) (with the stepped OD diameter 65mm) carefully to its stop in the
centering holes of the intermediate casing. Mount flat leakage seal (62D).
Important! The flat leakage seal (62D) must be positioned with its 3mm diameter bore onto
the notched pin (62C) on the intermediate casing. The leakage return bores in the interme-
diate casing and in the seal sleeves must remain clear of the cutouts in the seal (62D).
Push valve casing (50) together with intermediate casing (62) carefully on to the centering
studs (50A).
Tighten hexagon nuts evenly and crosswise to 265 Ft-lbs. (360 NM).
Important! 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.
Repair Instructions - GP8035 Pump

9
Repair Instructions - GP8035 Pump
11) Remove the connecting rod
screws (24).
Connecting rods are
marked 1 to 3 for identification. Do
not twist connecting rod halves or in-
terchange 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 crankshaft taking par-
ticular 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.
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 adapter (K11) and
remove gear cover (K3). Remove the cooling
vane plate (K1) by removing the screws (K4)

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14) Mount bearing cover (14A) and tighten screws (17) to 64 Ft-lbs. Adjust axial play (clear-
ance) 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. Pos-
sible axial float of the seal adapter (33) to be compensated with shims (33C).
Mount cooling plate (K1) and gear cover (K3) with their respective seals (K2). When as-
sembling the cooling circuit line, make sure that the oil cooler connection (K7) is always
joined to the upper connection (K3) of the gear cover.
Repair Instructions - GP8035 Pump