Plunger Pump Model Operating Instructions/ GXR …

1 TriplexPlunger PumpOperating Instructions/ Repair InstructionsManualConsumer PumpHorizontal/Vertical Pumpwith built-in Regulator,Thermal Relief Valve andSiphon InjectorModelGXR SeriesContents:Installation Instructions: page 2 Pump Specifications:page 3 Exploded View/Kits:page 4 Parts List:page 5 Torque Specifications:page 5 Repair Instructions:pages 6-7 Dimensions:back pageWarranty Information:back pageMADE IN THE USAU pdated 8/01 INSTALLATION INSTRUCTIONSIMPORTANT Operating CONDITIONSF ailure to comply with any of these conditions invalidates the Pump operation must not exceed ratedpressure, volume, or RPM. A pressure reliefdevice must be installed in the discharge of Acids, alkalines, or abrasive fluids cannot bepumped unless approval in writing is obtainedbefore operation from Giant Industries, Run the pump dry approximately 10 secondsto drain the water before exposure to Prior to initial operation, Check for proper oillevel.

2 DO NOT Giant Synthetic OilCrankcase oil should be changed after thefirst 50 hours of operation, then at regularintervals of 500 hours or less depending onoperating of the Giant Industries, Inc., pump is not a complicated procedure, but there are some basicsteps common to all pumps. The following information is to be considered as a general outline for instal-lation. If you have unique requirements, please contact Giant Industries, Inc. or your local distributorfor , remember that high pressure operation in a pump system has many advantages. But, if it is used carelesslyand without regard to its potential hazard, it can cause serious : Contact Giant Industries for Service School Information. Phone: (419)-531-46001. For horizontal applications the pump should beinstalled flat on a base to a maximum of a 15degree angle of inclination to ensure The inlet to the pump should be sized for theflow rate of the pump with no unnecessaryrestrictions that can cause cavitation.

3 Teflon tapeshould be used to seal all joints. Maximum inletfluid temperature is The discharge plumbing from the pump shouldbe properly sized to the flow rate to prevent linepressure loss to the work area. It is essential toprovide a safety bypass valve between the pumpand the work area to protect the pump frompressure spikes in the event of a blockage or theuse of a shut-off Use of a dampener is necessary to minimizepulsation at drive elements, plumbing, connections,and other system areas. The use of a dampener withGiant Industries, Inc. pumps is optional, althoughrecommended by Giant Industries, Inc. to furtherreduce system pulsation. Dampeners can also reducethe severity of pressure spikes that occur in systemsusing a shut-off gun. A dampener must be positioneddownstream from the Before beginning operation of your pumpingsystem, remember: Check that the crankcase and sealareas have been properly lubricated per recommendedschedules.

4 Do not run the pump dry for extendedperiods of time. Cavitation will result in severedamage. Always remember to check that all plumb-ing valves are open and that pumped media can flowfreely to the inlet of the GAS ENGINE HORSEPOWERREQUIREMENTS*RPM GPM 1000 PSI 1500 PSI 2000 PSI 2400 PSI3450 ELECTRIC HORSEPOWERREQUIREMENTSRPM GPM 1000 PSI 1500 PSI 2000 PSI 2400 PSI3450 GXR SeriesGXR2224 .. GPM @ 2400 PSIGXR2424 .. GPM @ 2400 PSIM aximum Inlet Pressure .. Up to 90 PSIG1 RPM .. 3450 Plunger Diameter .. 16mmStroke GXR2224 .. ( o angle)Stroke GXR2424 .. ( o angle)Crankcase Oil Capacity .. fl. oz. ( horizontal)Temperature of Pumped Fluids .. Up to 80 oFInlet Port .. 1/2" NPTD ischarge Ports .. 3/8" NPTS haft Rotation .. Either Direction2 Weight .. 9 .. "Height .. "Swash Plate Bore (Horizontal) .. 3/4" x 3/16" KeywaySwash Plate Bore (Vertical).

5 7/8" x 3/16" KeywayValve Type .. Polyamide Plastic1A 25 PSIG minimum inlet pressure is pump itself can be driven in either direction of rotation; however, the cooling fanon TEFC motors must always be positioned so that the cooling air is drawn from thenon-drive end of the motor towards the RATINGS:The rating shown are the powerrequirements for the pump. Gasengine power outputs must beapproximately twice the pumppower requirements shown recommend a service factorbe specified when selecting anelectric motor as the power compute specific pump horse-power requirements, use the Follow-ing formula:Electric HP = (GPM X PSI) / 1460 Gas HP = (GPM X PSI) / 1100* Engine power varies based on horizontal orvertical orientation as well as by makes andmodel from each GAS ENGINE HORSEPOWER REQUIREMENTS*RPM GPM 1000 PSI 1500 PSI 2000 PSI 2500 PSI3450 ELECTRIC HORSEPOWER REQUIREMENTSRPM GPM 1000 PSI 1500 PSI 2000 PSI 2500 PSI3450 SERIES EXPLODED VIEWP lunger Packing Kit# 09465 ItemPart #DescriptionQty.

6 2006290 Support Ring 3 2106315V-Sleeve 3 Valve Assembly Kit# 09466 ItemPart #DescriptionQty. 1807374 Valve Spring6 1906267 Guided P-Valve 3 3606295 Discharge Valve Cone 3 Oil Seal Kit# 09468 ItemPart #DescriptionQty. 1506316 Plunger Oil Seal 3 Regulator Repair Kit# 09534 ItemPart #DescriptionQty. 2423507O-Ring 1 2506710 Seat 1 2606386 Ball 1 2706385O-Ring 1 2806384 Plastic Poppet Valve 1 3006410O-Ring 1 ITEM# Part# Shaft Seal1206310*Adapting Flange1306294O-Ring1406300 Rear Bearing1506690**Wobble Plate Degree 3/4"(GXRH1114)1506566**Wobble Plate Degree 3/4"(GXRH2424)1506696+Wobble Plate Degree 7/8"(GXRV2224)1506322+Wobble Plate Degree 7/8"(GXRV2424)15A07882 Shaft Ring1606301 Front Bearing1706289 Spring Disk3806287 Plunger , 16mm3906288 Plunger Spring31006299 Socket Bolt61108192 Gasket11206273 Oil Drain Plug11306282 Crankcase (GXRV)11306338 Crankcase (GXRH)11408083 Vent Cap (Horizontal Only)

7 11506316 Oil Seal31706292 Spacer31807374 Valve Spring61906267 Guided P-Valve32006290 Pressure Ring32106315V-Sleeve, 16mm32206296 Discharge Plug3 GXR SERIES PARTS LISTITEM# Part# Ball12706385O-Ring12806384 Plastic Poppet Valve12906382 Spring13006410O-Ring13106392 Cap13506412 Manifold13606295 Discharge Valve Cone33807910 ATriangle O-Ring13906298 Suction Flange14006302 Stud Bolt444A06308 Orifice, , , in Nozzle14607913O-Ring14706303 Injector Retainer14823009 Spring14923010-0100 Ball15012516-0001 O-Ring15112517 Hose Barb15323422 AThermal Relief Valve154++07468 Locktooth Washer455++07467 Screws456++06334 Mounting Flange "X" Style1 PositionItem#DescriptionTorque Amount ( )1006299 Socket Bolt100 Bolt150 SERIES TORQUE SPECIFICATIONS* When ordering 06310, please order 17026, which includes 06300, 07805, and 06294.** When ordering 06566, please order 17047 which includes 06566, 06301, and 07882.

8 ** When ordering 06690, please order 17052 which includes 06690, 06301, and 07882.+ When ordering 06322, please order 17027 which includes 06322, 06301, and 07882.+ When ordering 06691, please order 17053 which includes 06691, 06301, and 07882.++ 09103 Gasoline Flange KitA = See pump numbering system page 7 REPAIR INSTRUCTION - GXR SERIES1. With a 14mm socket wrench,remove the three dischargevalve plugs (27). Inspectthe valve plug o-rings (23)for wear, and replace Remove the valve spring(18) and valve cone (36)from the manifold (35). In-spect the parts for wear andreplace as With a crescent wrench, re-move the injector retainer(47). Inspect the o-ring (46)for wear and replace as Next, remove the four mani-fold bolts (40) with a 6mmallen Remove the suction flange(39) and flange o-ring (38).Inspect the o-ring for wearand replace as Tap the back of the manifold(35) with a rubber mallet todislodge, and slide off theplungers.

9 (8). Take note ofthe position of the dischargeport so as to place the mani-fold in the same position dur-ing (inThremalPlate100 psiReliefShaftGX or HR SeriesFlowincrements)Injector Size ValveBoreVertical20=GPM 25=2500 PSI1= mm 1=1/2"1=3/4"Horizontal23=GPM2= "25=GPM3= "4=5/8"GX or - 111GX and HR Pump Part Numbering SystemFor example, a GXV2525-112 is a GX pump that produces GPM @ 2500 PSI, has a injector with Oriface, 1/2" thermal relief valve and 7/8" wobble plate SERIES REPAIR INSTRUCTIONS13. Reassemble in reverse the crankcase with theproper amount of oil (seespecifications page 3)The pump is now ready Remove the guided p-valve, (19), valve springs (18), v-sleeves(21) and pressure rings (20). Inspect for wear and replaceas necessary. Remove the spacer ring (17) from theplungers (8).12. If the crankcase oil seals (15)are to be replaced, they canbe removed by prying loosewith a screwdriver.

10 Take carenot to make contact with theplunger (8) and pry out theoil seals from their should not be rein-stalled until after step # : Contact Giant Industries forService School : (419)-531-4600 For maintenance of the gear end of yourpump, contact your local distributor orGiant Industries at: 419/531-460021 20 19 18 17 GIANT INDUSTRIES LIMITED WARRANTYG iant Industries, Inc. pumps and accessories are warranted by the manufacturer to be free fromdefects in workmanship and material as follows:1. For portable pressure washers and self-service car wash applications, the dischargemanifolds are guaranteed for the life of the pump. Our other pump parts, used inportable pressure washers and in car wash applications, are warranted for five yearsfrom the date of shipment for all pumps used in NON-SALINE, clean One (1) year from the date of shipment for all other Giant industrial and Six (6) months from the date of shipment for all rebuilt Ninety (90) days from the date of shipment for all Giant warranty is limited to repair or replacement of pumps and accessories of which the manufacturer sevaluation shows were defective at the time of shipment by the manufacturer.