Giant installation instructions Parts List GP8155-R, Replacing Valve Casing

GP8155-R PUMP REPAIR INSTRUCTIONS

Parts List - GP8155-R

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.

9)Coat the seal sleeve(39) 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 by 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 casing (50) and check o-rings (38A) (if necessary secure two 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:

10)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.

Item	Part	Description	Qty
1	05410	Crankcase	1
2	06893	Oil Filler Plug Assy with Vent	1
3	05411	Rear Foot for Crankcase	2
4	05412	Front Foot for Crankcase	2
5	05413	Hexagon Socket Screw	4
6	05414	Hexagon Socket Screw	4
7	05381	Plug 3/8 for Oil Dipstick	1
8	05035	Oil Dipstick Assy	1
9	01009	O-Ring	1
10	05415	Plug M33*1.5	1
11	07102	O-Ring	1
12	06273	Plug G3/8	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	05124	Clip Ring	1
20	05416	Tapered Roller Bearing	1
21	05417	Tapered Roller Bearing	1
21A	05042	Fitting Disc	3
21B	05043	Fitting Disc	3
21C	05113	Fitting Disc	3
22	05418	Crankshaft For Turned Gear	1
23	05419	Fitting Key	1
24	05047	Conn-rod Assy	3
25	05048	Crosshead c/w Plunger	3
28	05049	Crosshead Pin	3
29	05051	Hexagon Screw	6
29A	07408	Hexagon Nut	2
29B	05420	Bracket 2 for Cooling Hose	2
29C	05421	Support Clamp	2
29D	05422	Bracket 1 for Cooling Hose	1
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
36B	05280	Plunger Pipe	3
36C	05062	Tension Screw	3
36D	07665	Copper Washer	3
36E	06900	Centering Sleeve	3
38	05283	Seal Case	3
38A	13286	O-Ring	6
38B	05281	Support Ring	6
39	05275	Seal Sleeve	3
39A	05066	O-Ring	3
40	07723	Compact Ring	3
41	05276	Pressure Ring	3
42	05277	Sleeve	9
43	05278	Sleeve Support Ring	3
45	05279	Seal Tension Spring	3
49	05072	Stud Bolt	8
49A	05073	Hexagon Nut	8
50	05074	Valve Casing	1

Item	Part	Description	Qty
50A	13162	Centering Stud	2
50B	05075	Discharge Casing	1
51	05076	Suction Valve Assy.	3
51A	05077	Spring Tension Cap	3
51B	05078	Suction Valve Seat	3
51C	05079	Valve Plate	3
51D	07658	O-Ring	3
51E	05080	Valve Spring	3
51F	05081	Valve Spring Guide	3
52	05082	Discharge Valve Assy	3
52A	05077	Spring Tension Cap	3
52B	05084	Discharge Valve Seat	3
52C	05079	Valve Plate	3
52D	06258	O-Ring	6
52E	05080	Valve Spring	3
52F	05081	Valve Spring Guide	3
56	05085	Discharge Valve Adaptor	3
56A	06258	O-Ring	3
57	05086	Pressure Spring	3
57A	07210-0100	Pressure Spring	3
58	05087	Hexagon Socket Screw	12
59	07109	Plug G1/2	2
59A	06272	Copper Seal	2
60	06909	Plug G1 1/4	1
61	05088	Plug G3	1
62	05302	Plug G1/4	6
62A	06934	Copper Gasket	6
66	05423	Gear Cover	1
67	05424	Hexagon Screw	10
67A	07274	Washer	10
68	05425	Cylinder Pin	4
69	05426	Gear Wheel Set (2200 RPM=3.8)	1
70	07614	Fitting Key	1
72	05427	Hexagon Screw	1
73	05428	Shaft Seal Ring for Gear	1
74	05429	Roller Bearing	1
75	05430	Roller Bearing	1
75A	05431	Fitting Disc	1
76	05432	Gear Seal	2
77	05433	Flange c/w Gear	1
78	05025	Oil Cooler	1
79	07662	Mounting Aid for Valve	1
80	07544	Hexagon Socket Screw M8	1
81	05434	Hexagon Socket Screw	9
K1	05026	Cooling Vane Plate	1
K2	05027	Seal for Gear Cover	2
K3	05028	Gear Cover	1
K4	05029	Hexagon Hd Cntrsnk Screw	8
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 G1/2	2
K10	05120	Connecting Branch	3
K11	05032	U-Joint Connector c/w Nut	3
K12	05033	Tube for Cooler	2
K13	05402	Hose Clamp	4
K14	05435	Hose Guard	2
K15	05404	Hose Coupling Nut	1
K16	05436	Flat Gasket	4

8

5