Giant GP8076 User manual

Contents:
PumpSpecifications: page2
InstallationInstructions: page3
ExplodedView/PartsList: page4
PartsList: page5
RepairKits/ToolList:/TorqueSpecifications page6
RepairInstructions: page7
Dimensions: backpage
WarrantyInformation backpage
Triplex Ceramic
Plunger Pump
Models Manual
Model
GP8076

2
1) Figuresgivenformaximumpressureand
maximumspeed(rpm)applytointermittent
operationwithcoldwater.
Defi nition of intermittent operation:
Operationatfullperformancefornotmorethan
altogether20minutesanhour,withthepump
runningwithoutpressureorturnedoffinbetween.
Forexample,thiscanbefullloadoperationfor5
minutesfourtimesanhourwith10minutebreaks
inbetweenorcontinuousfullloadoperationfor20
minutesfollowedbya40minutebreak.
2)Higherwatertemperaturesarepossiblewitha
separateexternalcrankcasecoolingsystem.
Themanufactureristobecontactedinthiscase.
3)Themaximumpressureistobereducedby10%
wherecontinuousoperationwithacooler(withor
withoutgear)isinvolved.
NPSHR / Inlet pressure
RequiredNPSHreferstowaterat68°F(20°C)at
maximumpermissiblepumpspeed.
Theinletpressureonthesuctionsidemustnot
exceed29PSI(2bar).
Level of noise emission
Emissionsoundpressurelevel: ≤94dB(A)
1. Performance
U.S. (Metric)
Flow................................................................. 132GPM................. (500LPM)
DischargePressure......................................... 1500PSI................. (100bar)
PowerConsumption........................................ 129BHP................... 96kW
MaximumSpeed................................................................................ 520RPM
InletPressure.................................................. 29PSI..................... (2.0bar)
PlungerDiameter............................................. 2.99”......................... 76mm
PlungerStroke................................................. 2.83”......................... 72mm
CrankshaftDiameter........................................ 2.76”......................... 70mm
KeyWidth.......................................................................................... B20x12x10
CrankshaftMounting......................................................................... Eitherside
ShaftRotation.................................................................................... Topofpulleytowardsmanifold
TemperatureofPumpedFluids....................... 86oF ........................ (30oC)*
InletPorts.......................................................................................... (2)3”BSP
DischargePorts................................................................................. (2)1-1/4”BSP
Weight............................................................. 749lbs.................... (340kg)
CrankcaseOilCapacity................................... 3.3Gal.................... (12.5liters)
ValveCasingMaterial........................................................................ NickleplatedSpheroidalCastIron
NPSHR............................................................ 23.0ft.-head............. 7.0mWs
 *higherwatertemperaturespossiblewithseparatecrankcasecoolingsystem;contactGiant.
Specifi cations - GP8076
GP8076 HORSEPOWER REQUIREMENTS
RPM GPM 500PSI 1000PSI 1250PSI 1500PSI
260 66.0 22.8 45.5 56.9 68.3
300 76.2 26.3 52.6 65.7 78.8
400 102 35.2 70.4 87.9 105.5
520 132 45.5 91.0 113.8 136.6
2. Fields of application
Thefieldsofapplicationofthesepumptypes
correspondtothespecificationsintheassembly
instructionsGIANTINDUSTRIES.
Ambient conditions
Ambienttemperature:
41°F(5°C)<TAmb.<86°F(30°C)
4. Oil fi lling
• Fillingquantity: 3.3 gal (12.5 L)
• Quality: IndustrialgearoilISO VG
220orautomotivegearoil 
SAE 90 GL4 -
Giant’s p/n 01154
• Intervals: firstoilchangeafter50
operating hoursthenevery
1000 operating hours,butat
 thelatest12 months
If the pump is mounted on a vehicle
(possible inclined position during
operation) and/or if the pump speed is
between 300 rpm and 500 rpm, the
required oil quantity increases by 0.26
gallons (1 liter).

3
5. Installation/ Putting into Operation
5.1 Shaft protector
Whenthepumpisinoperation,thedrivenshaftside
andcouplingbyashaftguardandtheplungerroom
bycover(30).
Donotstepontotheprotectiveplate(30)norput
heavyobjectsonit.
5.2 Direction of pump rotation
Anarrowonthepumpcrankcaseindicatesthe
recommendeddirectionofrotationforthedriveshaft.
Theindicateddirectionensuresthatoiliscorrectly
distributedonandintothecrossheadguidesvia
optimalconnectingrodmotionthusprovidingbest
possiblelubricationparticularlywithregardto
continuousoperation.
Thepumpcanalsoberunagainsttherecommended
directionofrotationifoperatedperiodicallyorat
reducedpressure.
Ifso,thepumpmustberunininthisdirectionto
smoothenthebearingareas.
Thisisdonebyinitiallyoperatingthepumpatzero
pressurefor30minutes;thereafterthepressureisto
beslowlyincreasedoveraperiodofanhourtothe
desiredmaximumoperatingpressure.
Checktheoiltemperatureduringthisprocess.
5.3 Suction line fi lter
Recommendedmeshsize200μm.
5.4 Gear oil cooling
Thepumpscanberunwithoutgearoil
coolingincontinuousoperationup toa
powerratingof107.2 HP (80 kW)orwith
majorintermittentoperationatfull
performance.
Ifoperationalpowerexceeds 107.2 HP (80 kW)in
continuousoperation,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
approx.1.8GPM(7.0l/min.)atnominalspeed.The
coolingwaterissuckedinbyoneofthepumping
chambersandpumpedaway.
Ifhighermediumtemperaturesorliquids
otherthanwaterareinvolvedor
aggressivemediasuchasseawater,
demineralisedwateretc.,thepumpmust
befittedwithaseparatecoolingcircuit.
Theseparatecoolermusthaveacooling
efficiencyof1700watt.
Ifthereisadangeroffrost,anappropriateamountof
antifreezemustbemixedintothecoolingcircuit.
5.5 Valve Casing
Thetorquetensiononthevalvecasing
nuts(49A)istobecheckedafter
approximately200operatinghours.
Pleaseseethesection‘Maintenance
andServicing’concerningthetorque
values.
Thepumpmustbeatzeropressurewhenchecking
thetorquetension.
6. Operation
Whenstartingupforwork,thepumpmustrunfirst
atzeropressureforapproximately1minute.
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fittedonopen
vehiclestofreezeeveniftheoutside
temperatureisabovefreezingpoint.
Emptythepumpthroughthesecondunused
suctionanddischargeconnectionusing
compressedair,forexample.
Bottomplugs(12)onthesuctionchannelcanbe
openedaswell.
Thepumpcanalsoberun“dry”for1-2minutesto
aidemptying.
Emptythecoolingsystembyremovingscrewjoints
(K11)onthepumphead(50)andbyblowingthe
hoses(K12)withcompressedaironthe(K11/K7)
side.
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).

4
Exploded View - GP8076

5
Part List - GP8076
Item Part Description Qty
1 05380 Crankcase 1
2 06893 OilFillerPlugAssywithVent 1
5 22929 CopperWasher 2
6 12256 Plug,3/8”BSP 1
7 05656 PlugforOilDipstick 1
8 05035 OilDipstickAssembly 1
9 01009 O-Ring 1
12 07109 Plug1/2”BSP 2
13 06272 Seal 2
14 05036 BearingCoverClosed 1
14A 05298 BearingCoverOpen 1
15 05112 RadialShaftSeal 1
16 05037 O-Ring 2
17 05038 HexagonSocketScrew 16
18 05039 SpringRing 16
21 05044 TaperedRollerBearing 2
21A 05042 FittingDisc 1-5
21B 05043 FittingDisc 1-5
22 05299 Crankshaft 1
23 05104 FittingKey 1
24 05047 ConnectingRodAssembly 3
25 05048 Crossheadc/wPlunger 3
28 05049 CrossheadPin 3
29 05051 HexagonScrew 4
29A 05381 Bracket1forCoolingHose 2
29B 05383 Bracket2forCoolingHose 2
30 05052 CoverPlate 1
30A 07225-0100 HexagonScrew 5
30B 13136 Grommet 5
30C 05053 Washer 9
30D 05050 SplashCover 1
31 07623 EyeBolt 3
32 05058 RadialShaftSeal 3
32A 03118 Scraper 3
33 03119 SealRetainer 3
33A 05056 O-Ring 3
33B 05054 ClipRing 3
33C 05059 FittingDisc 3
34 03560 OilShield 3
36A 05063 CoverforPlungerPipe 3
36B 03561 PlungerPipe 3
36C 03562 TensionScrew 3
36D 03577 Washer 3
36E 06900 CenteringSleeve 3
36F 22704 O-Ring 3
36G 12092 O-Ring 3
38 03563 SealCase 3
38A 03564 O-Ring 6
39 03565 SealSleeve 3
39A 05066 O-Ring 3
40 03566 SupportRing 6
Item Part Description Qty
41 03567 GuideRing 6
42 03568 SpiralRing 6
45 03569 PressureSpring 3
49 05072 StudBolt 8
49A 05073 HexagonNut 8
50 03570 ValveCasing 1
50A 13162 CenteringStud 2
50B 03571 DischargeValveCasing 1
51 03572 ValveAssembly 6
51A 03573 SpringTensionCap 6
51B 03574 ValveSeat 6
51C 03575 ValvePlate 6
51D 06560 O-Ring 6
51E 05080 ValveSpring 6
51F 03434 O-Ring 6
56 03576 DischargeValveAdaptor 3
56A 04955 O-Ring 3
56B 13156 O-Ring 3
57 05086 PressureSpring 3
57A 07210-0100 PressureSpring 3
58 05087 HexagonSocketScrew 12
59 07109 Plug1/2”BSP 2
59A 06272 CopperSeal 2
60 13322 Plug1-1/2”BSP 1
61 05088 Plug3”BSP 1
62 05302 Plug1/4”BSP 6
62A 06934 CopperGasket 6
66 05303 DiscforCrankshaft 1
67 13433 HexagonScrew 1
68 07662 ValvePullerTool(Notshown)1
78 05025 OilCoolerAssembly 1
K1 05026 CoolingVanePlate 1
K2 05027 SealforGearCover 2
K3 05028 GearCover 1
K4 05029 HexagonHeadCountersunk
  Screw 4
K5 07381 HexagonSocketScrew 8
K6 08041 Washer 8
K7 05030 ConnectionforOilCooler 1
K8 06272 CopperSeal 6
K9 07109 Plug1/2”BSP 2
K10 05031 ConnectingBranch 3
K11 05032 HoseAdaptor 3
K12 05033 TubeforCooler 2
K13 05402 HoseClamp 4
K14 05403 HoseGuard 2
K15 05404 HoseCouplingNut 1
K16 05405 FlatGasket 4
K18 04158 HexagonSocketScrew 4
K19 05053 Washer 4

6
GP8076 PUMP REPAIR KITS
Plunger Packing Kit - #09861
Item Part# Description Qty.
38A 03564 O-Ring 6
39A 05066 O-Ring 3
40 03566 SupportRing 6
41 03567 GuideRing 6
42 03568 SpiralRing 6
Oil Seal Kit - #09584A
Item Part# Description Qty.
32 05058 RadialShaftSeal 3
32A 03118 Scraper 3
33A 05056 O-Ring 3
Valve Repair Kit - #09862
Item Part# Description Qty.
51B 03574 ValveSeat 6
51C 03575 ValvePlate 6
51D 06560 O-Ring 6
51E 05080 ValveSpring 6
51F 03434 O-Ring 6
56A 06258 O-Ring 3
56B 13156 O-Ring 3
GP8076 TORQUE SPECIFICATIONS
Position Item # Thread Description Lubricaion Info Torque Amount
12 07109 1/2”BSP Plug,1/2”BSP 59ft.-lbs.(80Nm)
15 05112 RadialShaftSeal Loctite403
17 05038 M12 HexagonSocketScrew 64ft.-lbs.(87Nm)
24 05047 M10 ConnectingRodAssembly 36.9ft.-lbs.(50Nm)
32 05058 RadialShaftSeal Loctite403
36C 03562 M10 TensionScrew Loctite243 30ft.-lbs.(40Nm)
39 03565 SealSleeve Anti-Seize350
CrankcaseSide
49 05072 M20 StudBolt Loctite648
CrankcaseSide
49A 05073 M20 HexagonNut 266ft.-lbs.(360Nm)
58 05087 M14 HexagonSocketScrew Anti-Seize350 103ft.-lbs.(140Nm)
59 07109 1/2”BSP Plug,1/2”BSP 59ft.-lbs.(80Nm)
K4 05029 M6 HexagonHeadCountersunkScrew 133in.-lbs.(15Nm)
K5 07381 M10 HexagonSocketScrew 33ft.-lbs.(45Nm)
K9 07109 1/2”BSP Plug,1/2”BSP 59ft.-lbs.(80Nm)
K18 04158 M6 HexagonSocketScrew 133in.-lbs.(15Nm)
Problem Cause Solution
Pressuredrops,waterleaks V-sleevesleak
ReplaceV-sleeves,examinesurfaceof
plunger
Dischargeorsuctionvalveleaks Replacevalve
Steamformation(cavitation)
Reducesuctionheight,reduceflowresistance
ininletline,cleaninletfilter,lowerwater
temperature
Wornvalves Examinevalves
O-Ringonthevalvesorinletvalve
adapterleaks
ExamineO-ring,examinevalvecasingfor
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
pressure
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
Pressuredrops,pump
becomesloud
Irregularpressure
GP8000 Troubleshooting

7
7. Maintenance and Servicing
Basedonthethreadtypeandtherequiredtightening
torques,observethetableonpage6.
7.1 Special tools required
Thefollowingspecialtoolsarerequiredforassembly:
-Assemblingtool(codeno.15.0038)
7.2 Suction and Discharge Valves
Loosenscrews(58),liftdischargevalvecasing(50B)
upandaway.
Takeoutpressuresprings(57).
Pulloutthecompletevalves(51)togetherwiththe
pressurevalveholder(56)usinganassemblytool
(orderno.07662).
To dismantle valves:
Thespringtensioncap(51A)isscrewedtogether
withthevalveseat(51B).
Screwoffspringtensioncap,takeoutsprings(51E)
andvalveplate(51C).
ChecksealingsurfacesandO-rings(51D,51F).
Replacewornparts.
Beforere-fittingthevalves,cleanthesealing
surfacesinthecasingandcheckforanydamage.
Tightenscrews(58)totherequiredtorque.
Checktorquetensionafter8-10operatinghours.
8.3 Seals and Plunger
Screwoffhexagonnuts(49A)andhosecoupling
(K11andK15),removepumpheadtogetherwithseal
case(38)fromcrankcase(1).
Ifnecessary,carefullytapthevalvecasing(50)past
thecentringstud(50A)usingarubberhammer.
Ifnecessary,supportthepumpheadby
restingitonwoodenblocksorbyusinga
pulley.
Removetensionscrew(36C)andtakesealsleeve
(39)togetherwithallmountedpartsoutofthedrive.
Pullplungerpipeoutofsealassemblyandcheckfor
anydamage.
Pulloutspiralrings(42),guiderings(41)andsupport
rings(40)andcheckforanydamage.
Becarefulnottodamagesealsleeve(39)
andguidering(41).
Checktheinnerdiameteroftheguidering
forwearandifnecessaryreplacetogether
withspiralring(42)andsupportring(40).
 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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valvecasing
(50)andcheckO-rings(38A)(ifnecessarysecure2
screwdriversinthefrontO-ringgroovetoextractseal
casingfromvalvecasing).
Coatsealswithsilicongreasebeforeinstalling.
 Mountingsurfacesofthecrankcaseand
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
centringpositionsinthecrankcase,
intermediatecasing,pressure-andvalve
casing.
 Theymuststandverticallyoneachother.
Coatthesealsleevelightlywithanti-corrosivegrease
(e.g.molycoteno.Cu-7439)initsfittedareatowards
thecrankcase.
Insertsealsleevesintotheircrankcasefittings.
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tensionscrewtotherequiredtorque.
Threadgluemustnevercomebetween
theplungerpipe(36B)andcentring
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-rings(38A,
39A)intothesealsleeve(39).
Mounting Valve Casing:
Putsealcases(38)inthecentringholesofthevalve
casing,thenpushvalvecasingcarefullyontocentring
studs(50A).
Tightenhexagonnutsevenlyandcrosswisetothe
requiredtorque.
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.
If required, supplementary assembly instructions
can be requested from the manufacturer Giant
Industries.
GP8076 PUMP REPAIR INSTRUCTIONS

07/23 GP8076.indd
GIANT INDUSTRIES, INC.
900N.WestwoodAve.
Toledo,Ohio43607
(419)531-4600
FAX(419)531-6836
www.giantpumps.com
©Copyright2023GiantIndustries,Inc.
GP8076 PUMP DIMENSIONS - (mm)
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. Five(5)yearsfromthedateofshipmentforallpumpsusedinportablepressure 
  washerswithNON-SALINE,cleanwaterapplications.
 2. Two(2)yearsfromthedateofshipmentforGiantpumpsusedincarwash  
  applications.
 3. One(1)yearfromthedateofshipmentforallotherGiantindustrialandconsumer 
  pumps.
 4. Six(6)monthsfromthedateofshipmentforallrebuiltpumps
 5. 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modificationsmadebythecustomerorthirdparty.
 6. Theoperationofpumpsandoraccessoriesexceedingthespecifications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.
THELIMITEDWARRANTYSETFORTHHEREINISINLIEUOFALLOTHER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.
WARNING:ThisproductmightcontainachemicalknowntotheStateofCaliforniatocausecancer,
andbirthdefectsorotherreproductiveharm.
Formoreinformationgotowww.P65Warnings.ca.gov