Giant GXR Series User manual

Triplex
Plunger Pump
Operating Instructions/
Repair Instructions
Manual
Consumer Pump
Horizontal/Vertical Pump
with built-in Regulator,
Thermal Relief Valve and
Siphon Injector
Model
GXR Series
Contents:
Installation Instructions: page 2
Pump Specications: page 3
Exploded View/Kits: page 4
Parts List: page 5
Torque Specications: page 5
Repair Instructions: pages 6-7
Dimensions: back page
Warranty Information: back page
Updated 10/09

INSTALLATION INSTRUCTIONS
4. Use of a dampener is necessary to mini-
mize pulsation at drive elements, plumbing,
connections, and other system areas. The
use of a dampener with Giant Industries, Inc.
pumps is optional, although recommended by
Giant Industries, Inc. to further reduce system
pulsation. Dampeners can also reduce the se-
verity of pressure spikes that occur in systems
using a shut-off gun. A dampener must be
positioned downstream from the unloader.
6. Before beginning operation of your pumping
system, remember: Check that the crankcase
and seal areas have been properly lubricated
per recommended schedules. Do not run the
pump dry for extended periods of time. Cavi-
tation will result in severe damage. Always
remember to check that all plumbing valves are
open and that pumped media can ow freely to
the inlet of the pump.
IMPORTANT OPERATING CONDITION
Failure to comply with any of these conditions invalidates the warranty.
If everything looks okay, continue to use
the pump. At least once per year (or every
200 hours), remove the oil from the pump and
replace with the required amount of oil. (See
page 3)
2. Pump operation must not exceed rated
pressure, volume, or RPM. A pressure relief
device must be installed in the discharge of
the system.
3. Acids, alkalines, or abrasive uids cannot
be pumped unless approval in writing is ob-
tained before operation from Giant Industries,
Inc.
4. Run the pump dry approximately 10 sec-
onds to drain the water before exposure to
freezing temperatures.
1. Prior to initial operation, Check for proper oil
level. DO NOT OVERFILL.
Use Giant Oil - P/N 01153
(20W-50 Synthetic)
Crankcase oil should be changed after the
rst 50 hours of operation, then at regular inter-
vals of 200 hours or less depending on operating
conditions.
Since it is difcult to determine the oil level in
the pump, check for signs of of oil leakage around
the pump before and during operation. The best
areas to check are between the manifold and the
crankcase and between the adapting plate and
the engine / motor mounting surface. Lastly, you
can see if there is any leakage around the vent
cap (on the top of the pump).
Installation of the Giant Industries, Inc., pump
is not a complicated procedure, but there are
some basic steps common to all pumps. The
following information is to be considered as
a general outline for installation. If you have
unique requirements, please contact Giant
Industries, Inc. or your local distributor for as-
sistance.
1. The pump should be installed at on a base to
a maximum of a 15 degree angle of inclination to
ensure optimum lubrication.
2. The inlet to the pump should be sized for the
ow rate of the pump with no unnecessary restric-
tions that can cause cavitation. Teon tape should
be used to seal all joints. Maximum inlet uid tem-
perature is 80oF.
3. The discharge plumbing from the pump should
be properly sized to the ow rate to prevent line
pressure loss to the work area. It is essential to
provide a safety bypass valve between the pump
and the work area to protect the pump from pres-
sure spikes in the event of a blockage or the use of
a shut-off gun.
Finally, remember that high pressure operation in a pump system has many advantages. But, if
it is used carelessly and without regard to its potential hazard, it can cause serious injury.
NOTE: Contact Giant Industries for Service School Information. Phone: [phone]
2

GXR2424 GAS ENGINE HORSEPOWER
REQUIREMENTS*
RPM GPM 1000PSI 1500PSI 2000PSI 2400 PSI
3450 2.4 2.2 3.3 4.4 5.2
GXR2424 ELECTRIC HORSEPOWER
REQUIREMENTS
RPM GPM 1000PSI 1500PSI 2000PSI 2400 PSI
3450 2.4 1.6 2.5 3.3 3.9
Specications
Model GXR Series
GXR2224..............................................................................................2.2 GPM (8.3 l/m) @ 2400 PSI
GXR2424..............................................................................................2.4 GPM (9.1 l/m) @ 2400 PSI
Maximum Inlet Pressure.......................................................................Up to 90 PSIG1
RPM......................................................................................................3450
Plunger Diameter...................................................................................63” (16mm)
Stroke GXR2224...................................................................................4.7mm (6.1 oangle)
Stroke GXR2424...................................................................................5.1mm (6.3 oangle)
Crankcase Oil Capacity ........................................................................4.7 . oz. (4.1 .oz. horizontal)
Temperature of Pumped Fluids.............................................................Up to 80 oF (26.6
O
C)
Inlet Port ...............................................................................................1/2” NPT
Discharge Ports .....................................................................................3/8” NPT
Shaft Rotation .......................................................................................Either Direction2
Weight...................................................................................................9 lbs. (4.1kg)
Width ....................................................................................................8.325”
Height....................................................................................................6.45”
Swash Plate Bore (Horizontal) .............................................................3/4” x 3/16” Keyway
Swash Plate Bore (Vertical)..................................................................7/8” x 3/16” Keyway
Valve Type............................................................................................Polyamide Plastic
1 A 25 PSIG minimum inlet pressure is required.
2 The pump itself can be driven in either direction of rotation; however, the cooling fan
on TEFC motors must always be positioned so that the cooling air is drawn from the
non-drive end of the motor towards the pump.
HORSEPOWER RATINGS:
The rating shown are the power
requirements for the pump. Gas
engine power outputs must be ap-
proximately twice the pump power
requirements shown above.
We recommend a 1.15 service factor
be specied when selecting an elec-
tric motor as the power source. To
compute specic pump horsepower
requirements, use the Following
formula:
Electric HP = (GPM X PSI) / 1450
Gas HP = (GPM X PSI) / 1100
* Engine power varies based on horizontal or
vertical orientation as well as by makes and
model from each manufacturer.
3

GXR SERIES EXPLODED VIEW
Plunger Packing Kit
# 09465
Item Part # Description Qty.
20 06290 Support Ring 3
21 06315 V-Sleeve 3
Valve Assembly Kit
# 09466
Item Part # Description Qty.
18 07374 Valve Spring 6
19 06267 Guided P-Valve 3
36 06295 Discharge Valve Cone 3
Oil Seal Kit
# 09468
Item Part # Description Qty.
15 06316 Plunger Oil Seal 3
Regulator Repair Kit
# 09534
Item Part # Description Qty.
24 23507 O-Ring 1
25 06710 Seat 1
26 06386 Ball 1
27 06385 O-Ring 1
28 06384 Plastic Poppet Valve 1
30 06410 O-Ring 1
4

ITEM# Part# Description QTY.
1 07805 Radial Shaft Seal 1
2 06310* Adapting Flange 1
3 06294 O-Ring 1
4 06300 Rear Bearing 1
5 06690** Wobble Plate 6.1 Degree 3/4”
(GXRH2224) 1
5 06566** Wobble Plate 6.3 Degree 3/4”
(GXRH2424) 1
5 06696+Wobble Plate 6.1 Degree 7/8”
(GXRV2224) 1
5 06322+Wobble Plate 6.3 Degree 7/8”
(GXRV2424) 1
5A 07882 Shaft Ring 1
6 06301 Front Bearing 1
7 06289 Spring Disk 3
8 06287 Plunger, 16mm 3
9 06288 Plunger Spring 3
10 06299 Socket Bolt 6
11 08192 Gasket 1
12 06273 Oil Drain Plug 1
13 06282 Crankcase (GXRV) 1
13 06338 Crankcase (GXRH) 1
14 08083 Vent Cap (Horizontal Only) 1
15 06316 Oil Seal 3
17 06292 Spacer 3
18 07374 Valve Spring 6
19 06267 Guided P-Valve 3
20 06290 Pressure Ring 3
21 06315 V-Sleeve, 16mm 3
22 06296 Discharge Plug 3
GXR SERIES PARTS LIST
ITEM# Part# Description QTY.
23 12007 O-Ring 3
24 23507 O-Ring 1
25 06710 Seat 1
26 06386 6mm S.S. Ball 1
27 06385 O-Ring 1
28 06384 Plastic Poppet Valve 1
29 06382 Spring 1
30 06410 O-Ring 1
31 06392 Cap 1
35 06412 Manifold 1
36 06295 Discharge Valve Cone 3
38 07910A Triangle O-Ring 1
39 06298 Suction Flange 1
40 06302 Stud Bolt 4
44A06308 Orice, 1.8mm 1
44A06339 Orice, 2.1mm 1
44A06340 Orice, 2.3mm 1
45 06312 O-Ring in Nozzle 1
46 07913 O-Ring 1
47 06303 Injector Retainer 1
48 23009 Spring 1
49 23010-0100 Ball 1
50 12516-0001 O-Ring 1
51 12517 Hose Barb 1
53 23422A Thermal Relief Valve 1
54++ 07468 Locktooth Washer 4
55++ 07467 Screws 4
56++ 06334 Mounting Flange “X” Style 1
Position Item# Description Torque Amount (ft.-lbs)
10 06299 Socket Bolt 100 in.-lbs.
40 06302 Stud Bolt 150 in.-lbs.
GXR 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.
** 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 Kit
A = See pump numbering system page 7
5

REPAIR INSTRUCTION - GXR SERIES
1. With a 14mm socket wrench,
remove the three discharge
valve plugs (27). Inspect
the valve plug o-rings (23)
for wear, and replace as
necessary.
2. Remove the valve spring
(18) and valve cone (36)
from the manifold (35). In-
spect the parts for wear and
replace as necessary.
3. With a crescent wrench,
remove the injector retainer
(47). Inspect the o-ring (46)
for wear and replace as nec-
essary.
8. Next, remove the four mani-
fold bolts (40) with a 6mm
allen wrench.
9. Remove the suction ange
(39) and ange o-ring (38).
Inspect the o-ring for wear
and replace as necessary.
10. Tap the back of the manifold
(35) with a rubber mallet to
dislodge, and slide off the
plungers. (8). Take note of
the position of the discharge
port so as to place the mani-
fold in the same position
during reassembly.
6

GXR SERIES REPAIR INSTRUCTIONS
13. Reassemble in reverse or-
der. Fill the crankcase with
the proper amount of oil
(see specifications page 3)
The pump is now ready for
operation.
11. Remove the guided p-valve, (19), valve springs (18), v-sleeves
(21) and pressure rings (20). Inspect for wear and replace
as necessary. Remove the spacer ring (17) from the
plungers (8).
12. If the crankcase oil seals (15)
are to be replaced, they can
be removed by prying loose
with a screwdriver. Take
care not to make contact
with the plunger (8) and pry
out the oil seals from their
housing. Seals should not
be reinstalled until after step
NOTE: Contact Giant Industries for
Service School Information.
Phone: [phone]
For maintenance of the gear end of your
pump, contact your local distributor or
Giant Industries at: 419/531-4600
21 20 19 18 17
Wobble
Pressure (in Thermal Plate
100 psi Relief Shaft
GX or HR Series Flow increments) Injector Size Valve Bore
Vertical 20=GPM 25=2500 PSI 1=2.1mm 1=1/2” 2=7/8”
Horizontal 23=GPM 2=1.8mm 1=3/4”
25=GPM 3=2.3mm 3=1”
4=5/8”
GX or HR 2.5 25 - 1 1 1
GX and HR Pump Part Numbering System
For example, a GXV2525-112 is a GX pump that produces 2.5 GPM @ 2500 PSI, has a injector with a
2.1mm Orice, 1/2” thermal relief valve and 7/8” wobble plate bore.
7

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. Forportablepressurewashersandself-servicecarwashapplications,thedischarge
manifolds are guaranteed for the life of the pump. Our other pump parts, used in
portable pressure washers and in car wash applications, are warranted for ve
years from the date of 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 manufac-
turer’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 Operations 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 work-
manship 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 war-
ranty consideration. 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
hereunderandthe MANUFACTURER SHALLNOTBE LIABLEFORFURTHERLOSS,DAMAGES,
OR EXPENSES, INCLUDING INCIDENTAL AND CONSEQUENTIAL DAMAGES DIRECTLY OR
INDIRECTLY ARISING FROM THE SALE OR USE OF THIS PRODUCT.
THE LIMITED WARRANTY SET FORTH HEREIN IS IN LIEU OF ALL OTHER WARRANTIES OR
REPRESENTATION, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION ANY WAR-
RANTIESORMERCHANTABILITYORFITNESSFORAPARTICULARPURPOSEANDALLSUCH
WARRANTIES ARE HEREBY DISCLAIMED AND EXCLUDED BY THE MANUFACTURER.
GXR Series
Dimensions
(inches)
10/09 GXR.PMD
GIANT INDUSTRIES, INC., 900 N. Westwood Ave., P.O. Box 3187, Toledo, Ohio
43607
PHONE [phone], FAX [phone], www.giantpumps.com
 Copyright 2009 Giant Industries, Inc.