Giant GP8135A User manual

Contents:
Installation/Operating Instructions: pages 2-3
Pump Specications: pages 4-5
Exploded View: page 6
Parts List: page 7
Repair Kits: page 8
Tool List/Torque Specications/
Troubleshooting Chart: page 8
Repair Instructions: pages 9-10
Dimensions: page 11
Warranty Information: back page
Triplex Ceramic
Plunger Pump
Operating Instructions
Repair and Service Manual
Models
GP8135A & GP8140A
Pumps without oil cooling systems

2
INSTALLATION INSTRUCTIONS
The stated gures are fore maximum
pressure and maximum. speed (rpm)
and apply for interval operation with cold
water.
Required NPSH refers to water (specic
weight 0.062 lbs/ft3- 1kg/dm3, viscosity
1° E) at maximum permissible pump
revolutions.
Fluid medium: Clean water ltered to 50
microns.
For higher water temperatures, use a
separate crankcase cooling system, for
details contact Giant Industries.
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
ttings (particularly the unloader valve)
must me emptied. The second discharge
port can also be used and the pump run
“dry” for 1-2 minutes for this purpose.
The following oils may be use: 85-90W
Industrial Gear Lube oil (Giant’s p/n
01154), or ISO VG 220 GL4 (e.g. Aral
Degol BG220) or SAE 90 GL4 gear
oil. Use 4.2 gallons (16 liters of one of
the above oils). 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
uctuations condensate (frothy oil) might
appear in the gearbox. The oil must be
changed immediately.
NPSH values must be observed.
Cooling the Gear Oil
Make sure that suction pulsation is
sufciently dampened; water column
resonance must be avoided.
Denition of intermittent operation:
operation at full performance for not more
than 20 minutes per hour (total time).
This means the pump can run with no
pressure or it is completely stopped. 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.
When starting up for work, the pump must
run rst at zero pressure for approximately
1 minute.
Important! The GP8135A/GP8140A
pumps have a black arrow on the
reduction gear, which shows the preferred
direction of rotation. The pumps can be
delivered either with the gear on the left
side or the right side, which eases the
planning of assembling units with regard
to rotational direction.
Gear on left side (from the front of the
pump) = optimal rotation: to the left
(counterclockwise)
Gear on the right side (from the front of
the pump) = optimal rotation to the right
(clockwise)
The preferred/optimal direction of rotation
ensures the motion of the connecting rods
correctly slings the oil onto the crosshead
guides. Where continuous operation is
involved, this is a particular advantage.
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 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

3
the desired maximum operating pressure;
the pump is then run in. Check the oil
temperature during this process.
Important! The pump must be emptied
if there is a danger of frost. Travel wind
can cause water in pumps tted on open
vehicles to freeze even if the outside
temperature is above freezing point.
The torque tension on the valve casing
nuts (49A) should be checked after
approximately 200 hours. Please see the
section “Torque Specications” on page 8.
When checking the torque tension, the
pump must be at zero pressure.
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 examined every day;
the plunger seals must be changed should
leakage become excessive (i.e. constant
dripping).
!Safety Rules!
Before performing any work on the
pump or complete assembled unit,
the operating instructions must be
read and followed. Giant will not bear
responsiblity for damage to materials
or persons caused by improper
handling of our pumps.
For unauthorized personnel, access to
the pump is not allowed. A safety valve
is to be installed in accordance with the
guidelines for liquid spraying units so that
the admissible operating pressure cannot
be exceeded by more than 10%. Pump
operation without a safety valve as well as
any excess in temperature or speed limits
automatically voids the warranty.
INSTALLATION INSTRUCTIONS
When the pump is in operation, a
protective guard must cover the driven
shaft side and its coupling. The plunger
area must also be cover by the protective
plate (30).
Do not step onto the protective plate (30)
nor put weight on it.
Pressure in the discharge line and pump
must be at zero before carrying out any
maintenance work to the pump or unit.
Close off suction line. Disconnect fuses to
ensure that the driving motor cannot get
switched on accidentally. Make sure that
the pump, the cooling system and all parts
on the pressure side of the unit are vented
and relled, with pressure at zero, before
starting the pump.
In order to prevent air or an air/water-
mixture being absorbed and cavitation
occurring, the pump-npshr, positive
suction head and water temperature must
be respected.
Cavitation and/or compression of
gases lead to uncontrollable 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 suitable for
pumping clean water and other non-
aggressive or nonabrasive media with a
specic weight similar to water.
Before pumping other liquids-
especially inammable, explosive and
toxic media-the pump manufacturer
must be consulted with regard to the
resistance of the pump material. It is
the responsibility of the equipment
manufacturer and/or operator to
ensure that all pertinent safety
regulations are adhered to.

4
HORSEPOWER RATINGS:
The rating shown are the power require-
ments for the pump. Gas engine power outputs
must be approximately twice the pump power
requirements shown above.
We recommend a 1.15 service factor be
specied when selecting an electric motor as the
power source.
To compute specic pump horsepower
requirements, use the following formula:
GPM X PSI
1450
Specications
Model GP8135A
U.S.................................... (Metric)
Flow ................................................................. up to 29.1 GPM* ............... (110 LPM)*
Discharge Pressure ......................................... up to 7250 PSI*................. (500 bar)*
Power Consumption ........................................ 94 BHP* ............................ 70 kW*
Maximum Crankshaft Speed ...................................................................... 580 RPM
Inlet Pressure .................................................. Up to 145 PSI .................. (10 bar)
Plunger Diameter............................................. 1.38”.................................. 35 mm
Plunger Stroke................................................. 2.83”.................................. 72 mm
Pinion Shaft Diameter...................................... 1.77”.................................. 45 mm
Fitting Key .................................................................................................. 14 mm x 70 mm
Crankshaft Mounting .................................................................................. Either side
Pinion Shaft Rotation.................................................................................. Towards Gear End of pump
Temperature of Pumped Fluids ....................... Up to 86 oF ....................... (30 oC)
Inlet Ports ................................................................................................... (2) 2” NPT
Discharge Ports .......................................................................................... (2) 1” NPT
Weight ............................................................. 800 lbs. ............................. (363 kg)
Crankcase Oil Capacity ................................... 4.2 Gal. ............................ (16.0 liters)
Fluid End Material....................................................................................... Stainless Steel
NPSHR ............................................................ 27.8 ft. - head.................... 8.5 mWs
Based on driver type, input speeds may vary.
* Do not exceed 94 BHP (70 kW).
Consult the factory for special requirements that must be met if the pump is to
operate beyond one or more of the limits specied above.
SPECIAL NOTE:
The theoretical gallons per revolution (gal/rev) is
0.050.
To nd specic outputs at various RPM, use the
formula:
GPM = 0.050 x RPM
= HP
GP8135 HORSEPOWER
REQUIREMENTS
RPM GPM 1000 PSI 2500 PSI 5000 PSI 7250 PSI
300 15.1 10.4 26.0 52.1 75.5
375 18.8 13.0 32.4 64.8 94.0
500 25.1 17.3 43.3 86.6 N/A
580 29.1 20.1 50.2 N/A N/A
GP8135 Gear Ratios
Gear Ratio Input Speed
2.6:1 1500 RPM
3.1:1 1800 RPM
3.8:1 2200 RPM
4.5:1 2600 RPM

5
Specications
Model GP8140A
U.S......................................(Metric)
Flow ................................................................. up to 39.6 GPM* .................(150 LPM)*
Discharge Pressure ......................................... up to 5510 PSI*...................(380 bar)*
Maximum Crankshaft Speed ........................................................................580 RPM*
Power Consumption ........................................ 94 BHP................................70 kW
Inlet Pressure .................................................. Up to 145 PSI ....................(10 bar)
Plunger Diameter............................................. 1.57”....................................40 mm
Plunger Stroke................................................. 2.83”....................................72 mm
Pinion Shaft Diameter...................................... 1.77”....................................45 mm
Fitting Key ....................................................................................................14 mm x 70 mm
Crankshaft Mounting ....................................................................................Either side
Pinion Shaft Rotation....................................................................................Towards Gear End of pump
Temperature of Pumped Fluids ....................... Up to 86 oF .........................(30 oC)
Inlet Ports .....................................................................................................(2) 2” NPT
Discharge Ports ............................................................................................(2) 1” NPT
Weight ............................................................. 800 lbs. ...............................(363 kg)
Crankcase Oil Capacity ................................... 4.2 Gal. ..............................(16.0 liters)
Fluid End Material.........................................................................................Stainless Steel
NPSHR ............................................................ 24.6 ft.-head........................7.5 mWs
Based on driver type, input speeds may vary.
* Do not exceed 94 BHP (70 kW).
Consult the factory for special requirements that must be met if the pump is to
operate beyond one or more of the limits specied above.
HORSEPOWER RATINGS:
The rating shown are the power require-
ments for the pump. Gas engine power outputs
must be approximately twice the pump power
requirements shown above.
We recommend a 1.15 service factor be
specied when selecting an electric motor as the
power source.
To compute specic pump horsepower
requirements, use the following formula:
GPM X PSI
1450
SPECIAL NOTE:
The theoretical gallons per revolution (gal/rev) is
0.068.
To nd specic outputs at various RPM, use the
formula:
GPM = 0.068 x RPM
GP8140 HORSEPOWER
REQUIREMENTS
RPM GPM 1000 PSI 2500 PSI 3500 PSI 5510 PSI
300 20.5 14.1 35.3 49.5 77.9
362 24.7 17.0 42.6 59.6 93.9
500 34.1 23.5 58.8 82.3 N/A
580 39.6 27.3 68.3 N/A N/A
GP8140 Gear Ratios
Gear Ratio Input Speed
2.6:1 1500 RPM
3.1:1 1800 RPM
3.8:1 2200 RPM
4.5:1 2600 RPM
= HP

6
EXPLODED VIEW - GP8135 & GP8140

7
Parts List - GP8135 and GP8140
Item Part Description Qty
1 05651 Crankcase 1
2 06893 Oil Filler Plug Assy with Vent 1
3 05652 Rear Foot for Crankcase 2
4 05653 Front Foot for Crankcase 2
5 05654 Hexagon Socket Screw 4
6 05655 Hexagon Socket Screw 4
7 05656 Plug 3/8” BSP for Oil Dipstick 1
8 04185 Oil Dipstick Assy 1
9 01009 O-Ring 1
10 05657 Plug M33 X 1.5 1
11 07102 O-Ring 1
12 12256 Plug 3/8” BSP 3
13 22929 Copper Washer 4
14 05036 Bearing Cover Closed 1
16 05037 O-Ring 1
17 05038 Hexagon Socket Screw M12 8
18 05039 Spring Ring 8
19 05765 Flange 1
19A 05766 Hexagon Socket Screw 6
20 05658 Tapered Roller Bearing 1
21 05659 Tapered Roller Bearing 1
21A 05042 Fitting Disc 1-3
21B 05043 Fitting Disc 1-3
21C 05113 Fitting Disc 1-3
22 05741 Crankshaft For GP8100 1
23 05661 Fitting Key 1
24 05047 Connecting Rod Assy. 3
25 05048 Crosshead with Plunger Base 3
28 05049 Crosshead Pin 3
29 05051 Hexagon Screw 4
30 05052 Cover Plate 1
30A 07225-0100 Hexagon Screw 5
30B 13136 Grommet 5
30C 08280 Washer 9
30D 05050 Splash Cover 1
31 07623 Eye Bolt 4
32 05058 Radial Shaft Seal 3
33 05055 Seal Retainer 3
33A 05056 O-Ring 3
33B 05054 Clip Ring 3
33C 05059 Fitting Disc 3
34 05060 Oil Shield 3
34A 05830 Locking Disc 3
36 05743 Plunger Pipe, GP8135 3
36 05816 Plunger Pipe, GP8140 3
38 05831 Seal Case, GP8135 3
38 05817 Seal Case, GP8140 3
38A 05408 O-Ring, GP8135 6
38A 05818 O-Ring, GP8140 6
39 05832 Seal Sleeve, GP8135 3
39 05819 Seal Sleeve, GP8140 3
39A 05617 O-Ring 3
40 05744 Sleeve, GP8135 3
40 05820 Sleeve, GP8140 3
40A 05745 O-Ring, GP8135 3
40A 05821 O-Ring, GP8140 3
40B 05746 Pressure Ring, GP8135 3
40B 05822 Pressure Ring, GP8140 3
40C 05474 Clip Ring, GP8135 3
40C 13217-0100 Clip Ring, GP8140 3
41 05833 Pressure Ring, GP8135 3
41 05823 Pressure Ring, GP8140 3
41A 05747 Guide Ring, GP8135 3
41A 05824 Guide Ring, GP8140 3
42 05748 Rope Packing, GP8135 6
42 05825 Rope Packing, GP8140 3
43 05749 Support Disc, GP8135 3
43 05826 Support Disc, GP8140 3
44 05751 Support Ring, GP8135 6
44 05827 Support Ring, GP8140 3
Item Part Description Qty
45 06098 Tension Spring, GP8135 3
45 05828 Tension Spring, GP8140 3
49 05834 Stud Bolt 8
49A 05073 Hexagon Nut 8
50 05835-NPT Inlet Valve Casing 1
50A 13162 Centering Stud 2
50B 05836-NPT Discharge Valve Casing 1
51 05837 Inlet Valve Assembly 3
51A 05595 Spring Tension Cap 3
51B 05838 Inlet Valve Seat 3
51C 05752 Valve Plate 3
51D 05408 O-Ring 3
51E 05450 Valve Spring 3
51F 05596 O-Ring 3
52 05839 Discharge Valve Assy. 3
52A 05595 Spring Tension Cap 3
52B 05840 Discharge Valve Seat 3
52C 05752 Valve Plate 3
52D 05408 O-Ring 6
52E 05450 Valve Spring 3
52F 05596 O-Ring 3
56 05409 Discharge Valve Adaptor 3
56A 05408 O-Ring 3
57 07173 Tension Spring 6
58 05753 Inner Hexagon Screw 12
59 07109 Plug, 1/2” BSP 2
59A 06272 Copper Seal, 1/2” BSP 2
62 05842 Intermediate Casing 1
62A 05843 Flat Seal 1
62B 05754 Hexagon Socket Screw 4
62C 22764 Serrated Pin 4
62D 05844 Flat Leakage Seal 3
62E 06106 Allen Grub Screw 2
62F 04583 Connector 1
63 05845 Drip Return Joint 2
63A 05757 Leakage Seal 2
63B 05811 Hexagon Socket Screw 4
64 05846 Drip Return Nipple 2
64A 11507-0001 O-Ring 6
65 05847 Drip Return Connection 1
65A 05848 Drip Return Plug 1
66 05663 Gear Cover 1
67 05664 Hexagon Screw 10
67A 05341 Washer 10
68 04445 Cylinder Pin 2
69 04171 Wheel Set (1500 RPM=2.6) 1
69 04170 Wheel Set (1800 RPM=3.1) 1
69 05767 Wheel Set (2200 RPM=3.8) 1
69 05666 Wheel Set (2600 RPM=4.5) 1
70 07614 Fitting Key 1
71 04571 Fitting Disc 1
72 05667 Hexagon Screw 1
73 05608 Shaft Seal Ring for Gear 1
74 05815 Roller Bearing 1
75 05669 Roller Bearing 1
75A 05670 Fitting Disc 1
76 05432 Gear Seal 1
07662 Valve Puller (not shown) 1
K2 05027 Seal for Gear Cover 1
K3 05028 Gear Cover 1
K5 22706 Hexagon Socket Screw 8
K6 08041 Washer 8
K8 06272 Copper Seal 4
K9 07109 Plug, 1/2” BSP 4
K18 04614 Hexagon Set Screw 4
K19 05053 Washer 4
04159-NPT Pump Head Assembly (50-65A w/o 50A)
04175 Plunger Replacement Kit, GP8135 (34A-45)
04160 Plunger Replacement Kit, GP8140 (34A-45)

8
TROUBLESHOOTING
Problem Cause Solution
Pressure Drops, water leaks V-sleeves leak Replace V-sleeves, check surface of
plunger
Pressure drops, pump gets loud Discharge or suction valve leaks Replace valve(s)
Steam formation (Cavitation) Reduce suction height, reduce ow
resistance in inlet line, clean inlet
lter, lower water temperature.
Irregular pressure Worn Valves Examine valves
O-ring on valves or inlet valve
adapter leaks Examine O-rings, check valve
casing for unevenness on the
sealing surfaces
Oil leaks at visible part of plunger Gear sealing is leaking Examine seals and running surface
of plunger
Dirty, milk-colored or frothy oil Water has mixed with oil Replace oil immediately, nd & x
the cause
Oil leakage on the crankshaft 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
specied lubricants are to be used.
Pump Repair Kits - GP8135 and GP8140
Plunger Packing Kit - GP8135 - # 09707
Item Part # Description Qty.
38A 05408 O-Ring 6
39A 05617 O-Ring 3
40 05744 Sleeve 3
40A 05745 O-Ring 3
41A 05747 Guide Ring 3
42 05748 Rope Packing 6
44 05751 Support Ring 6
Plunger Packing Kit - GP8140 - # 09708
Item Part # Description Qty.
38A 05818 O-Ring 6
39A 05617 O-Ring 3
40 05820 Sleeve 3
40A 05821 O-Ring 3
41A 05824 Guide Ring 3
42 05825 Rope Packing 3
44 05827 Support Ring 3
Inlet Valve Kit - #09709
Item Part # Description Qty.
51 05837 Inlet Valve Assembly 3
56A 05408 O-Ring 3
Discharge Valve Kit - #09710
Item Part # Description Qty.
52 05839 Discharge Valve
Assembly 1
Oil Seal Kit - #09584
Item Part # Description Qty.
32 05058 Radial Shaft Seal 3
33A 05056 O-Ring 3
Tool List and Torque Specications - GP8135/GP8140
Item Part # Description Torque - Ft-lbs (NM) Tool Needed
17 05038 Hexagon socket screw 64 (87) 10 mm allen wrench
24 05047 Connecting rod hexagon socket screw 37 (50) 8 mm allen wrench
33B 05054 Clip ring n/a Industrial snap ring pliers
36 05743/05816 Tension screw, plunger assemlby 33 (45) 16 mm socket
49A 05073 Hexagon nut, manifold 265 (360) 30 mm socket
51/52 05837/05839 Valve Assemblies n/a Valve Puller - p/n 07662
58 05753 Hexagon socket screw 132 (180) 12 mm allen wrench
K5 22706 Hexagon socket screw n/a 8 mm allen wrench

9
To Check Valves
Loosen screws (58) and lift discharge casing (50B) up and away. Take out pressure springs (57). Pull out as-
sembled valves (51 and 52) with tting 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.
When reassembling, coat threads of valve seat with silicon grease or molycote anti-seize Cu-7439. Before
retting 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
Remove hexagon nuts (49A). 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 at leakage seal (62D) and check to make sure that it is not torn or damaged.
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-surface of crosshead
with plunger base (25). Take out tension spring (45). Carefully remove the whole seal unit (41-44) by using
socket wrench or the backside of a screwdriver. Check plunger surface and seals. Check O-rings (39).
Renew damaged parts.
After removing clip-ring (40C) and pressure ring (40B), check leakage seal (40) and O-ring (40A) . If neces-
sary, replace worn parts.
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 necessary, replace together with seals
(42) and support ring (44). Clean all parts. Before installation, new parts should be lightly coated with silicon
grease.
Insert the seal unit (41-45) into the seal sleeve (39). Carefully push the plunger (36) through the seals (from
the crankcase side). If necessary, the seals can be held tightly using a suitable pipe support held on the op-
posite 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. Before installing, coat
O-rings with silicon grease.
Important! Mounting surfaces of the crankcase, seal sleeves, intermediate casing and valve casing must be
clean and free of damage. The components must t exactly and evenly on one another. The same exactness
applies for all centering positions in the crankcase, intermediate casing, pressure-and valve casing.
Coat the seal sleeve lightly with anticorrosive grease (e.g. molycote no. Cu-7439) in its tted area towards the
crankcase. Insert seal sleeves in to their crankcase ttings.
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 base (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).
GP8135 and GP8140 Pump Repair Instructions

10
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 at leakage seal (62D).
Important! The at 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 intermediate 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.
To Dismantle Reduction Gear
Take out plungers and seal sleeves (as described above). Drain oil by taking off plug (12). After removing
the clip ring (33B), pry out the seal retainer (33) with a screwdriver. Remove gear cover (K3) by removing the
screws (K5). Remove connecting rod screws (24).
Important! Connecting rods are marked for identication. Do not twist connecing rod halves or interchange
them. When reassembling, the connecting rods must be tted in their exact original position on the crank-
shaft journals. Push connecting rod halves together with the crosshead as far as possible into the crosshead
guide. Remove bearing cover (14), remove shims (21A/B).
To Dismantle Reduction Gear
Remove screws (67). Press off gear cover (66) by screwing two screws into both thread bores. Remove
screw (72) and take off tting disc (69). Remove the cogwheel from the shaft with a bearing puller tool. Using
a rubber hammer, tap out the crankshaft towards bearing cover (14). 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.
Reassemble in reverse order. Thread the crankshaft in from the bearing cover side until the bearing rests
cleanly in the outer ring on ange (19).
Press in the outer ring from bearing (20) and use shims (21A/B), adjust the bearing to be free of play. To
achieve this, add shims, screw on cover (14) and turn the crankshaft until it can no longer 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 and connecting rods due to axial movements in the conical
bearing shells. Mount connecting rod halves in their exact original position and tighten at 37 Ft.-Lbs. (50 NM).
Important! Connecting rods must be able to move slightly sideways on the stroke journals.
To Mount Reduction Gear
Before pressing the ball bearings (75 and 74) onto the pinion, heat them up. Press the cogwheel slightly on to
the crankshaft so that the pinion (69) together with the bearing (74) can still be inserted.
Move the pinion (69) against the cogwheel and make them mate perfectly when mounting. Then carefully tap
the cogwheel and the pinion simultaneously on to the crankshaft and into the bearing seat.
Fit tting disc (69), and secure screw (72) with Loctite. Fit the seal (76) on to the cylindrical pins (68). Care-
fully push the gear cover (66) onto the bearing (75). Make sure that the radial shaft seal (73) does not be-
come damaged during tting on to the pinion shaft.
With their respective seals (K2), mount gear cover (K3).
Important! Before putting in to operation again, turn the reduction gear shaft per hand at least four full turns
to make sure the gear is correctly aligned.
GP8135 and GP8140 Pump Repair Instructions

11
GP8135 and GP8140 Pump Dimensions- Inches (MM)

GIANT INDUSTRIES, INC., 900 N. Westwood Ave., P.O. Box 3187, Toledo, Ohio 43607
PHONE [phone], FAX [phone], www.giantpumps.com
 Copyright 2016 Giant Industries, Inc.
06/16 GP8135A_GP8140A.INDD
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 neverfail, 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 ve 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 modications made by the customer or third party.
6. The operation of pumps and or accessories exceeding the specications set forth in the Opera-
tions 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 workman-
ship 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 consid-
eration. Call (419)-531-4600 or fax [phone] 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 INDI-
RECTLY ARISING FROM THE SALE OR USE OF THIS PRODUCT.
THE LIMITED WARRANTY SET FORTH HEREIN IS IN LIEU OF ALL OTHER WARRANTIES OR REP-
RESENTATION, 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.