2
INSTALLATION INSTRUCTIONS
NOTE: Contact Giant Industries for Service School Information. Phone: (419)-531-4600.
Operation and Maintenance
Check oil level prior to starting and ensure trouble-free water
supply.
Oil:
Use only 1.6 gallons (6.0 liters) of SAE 80W-90 Industrial
Gear Lube Oil (Giant’s p/n 01154).
IMPORTANT!
If the pump is mounted on a vehicle with the
possibility of unlevelness and/or the pump speed is between
300 & 500 RPM, the volume of oil should be 2 gallons (7.5
liters). To check, put the oil dipstick in the bore situated next to
the eye bolt.
Initial change after 50 hours and then after every 500 operating
hours. If used less than this, change once per year.
IMPORTANT!
When operating in humid areas (or areas
with large temperature fluctuations, the oil must be changed
immediately (if condensate or frothy oil occurs in the
crankcase).
I
MPORTANT!
We recommend that both inlet ports be used in
order to ensure cavitation-free operation and optimal suction
conditions. If only one connection is use, a safety margin of 3
feet (1 meter) has to be added to the required NPSH.
IMPORTANT!
The GP7645GB, GP7650GB and GP7655GB
pumps have a black arrow on the reduction gear, which shows
the preferred direction of rotation. The pump can be delivered
either with the gear on the left side or right side (when facing
the front of the pump), which eases planning assembled units
with regard to the desired direction or rotation.
In either case,
the larger gear wheel must rotate towards the front-end of
the pump.
The preferred/optimal direction of rotation ensures that the oil
is correctly splashed on the crosshead guides via the motion
of the connecting rods, which is a particular advantage where
continuous operation is involved.
The pump can also be run against the recommended direction
of the rotation if operated periodically or at reduced pressure.
If this is the case, 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
the desired maximum operating pressure. This should run-in
the pump, but you should also check the oil temperature,
which should not exceed 160
o
F (71
o
C).
The torque tension on the valve casing nuts (49A) is to be
checked after approximately 200 hours. Please see page 6 for
torque values.
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 examine every day. If the leakage becomes excessive
(constant dripping), the plunger seals must be changed.
Safety Rules
The operating instructions must be read and adhered to
before performing any work on the pump or complete
assembled unit. No responsibility will be carried by us
for damage to materials or persons
caused by improper
handling of our pumps
.
Access to the pump is not allowed by unauthorized personnel.
As 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%.
Pumps operating without a safety valve as well as any excess
in temperature or speed limits automatically voids the warranty.
When the pump is in operating, the exposed shaft side, the driven
shaft side and its coupling must be covered by a protective guard.
The plunger area must also be covered by the protective plate
(30). Do not step onto the protective plate (30 ) or put weight on
it.
Before carrying out any maintenance work to the pump or pump
unit, the pressure in the discharge line and pump must be at zero.
Close off the suction line. Disconnect fuses to ensure that the
driving motor cannot accidently get switched on. Before starting
the pump, make sure that the pump, the cooling system and all
parts on the pressure side of the unit are vented and refilled with
pressure at zero.
In order to prevent air or air/water-mixture being absorbed and
cavitation occurring, the pump NPSHR (Net Positive Suction
Head Required) and water temperature must be adhered to.
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 only suitable for pumping fresh clean
water.
Cooling the Gear Oil
IMPORTANT!
The water input pressure must not exceed 29 PSI
(2 bar) when using the integrated system for cooling the gear oil
(standard version).
If a separate cooling circuit (maximum 29 PSI [2 bar]) is installed,
it is then possible to have an input pressure of up to maximum
145 PSI (10 bar) on the suction side.
Make sure that suction pulsation is sufficiently dampened - water
column resonance must be avoided.
IMPORTANT!
The pumps can be run without gear oil cooling in
continuous operation
up to
a power rating of
80 hp (60 kW)
or
with major intermittent operation).
If operation power
exceeds 80 hp (60 kW)
or if continuous
operation is the case, the pump must be run with the integrated
oil cooling system. The maximum temperature of the water
being pumped and which is also fed through the cooling system
must not exceed 86 °F (30°C). The amount which is fed into the
cooling system depends on the pump speed and is approximately
1.5 GPM (5.5 L/min) at 800 RPM. The cooling water is sucked in
by one of the pumping chambers and pumped away.
IMPORTANT!
The pump and cooling system must be emptied if
there is a danger of frost. Note that travel wind can cause water
in pumps fitted on open vehicles to freeze even if the outside
temperature is above freezing point.
To empty the colling circuit, remove the L-joints (K11) on the
pump head (50). Blow out the circuit liquid (hoses K12) at the
joint connection (K11/K7) using compressed air.
The torque tension on the valve casing nuts (49A) is to be
checked after approximately 200 operating hours. Please refer to
the section “Maintenance” concerning the torque values.
The pump must be at zero pressure when checking the torque
tension.
