Giant GP8045 installation instructions Replacing Valve Casing

GP8045/GP8048 PUMP REPAIR INSTRUCTIONS

7) Be careful not to damage the seal 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.

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.

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).

8)Take out the seal case (38) from the valve (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 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:

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.

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