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 Specifications: page 3
Exploded View/Kits: page 4
Parts List: page 5
Torque Specifications: page 5
Repair Instructions: pages 6-7
Dimensions: back page
Warranty Information: back page
MADE IN THE USA
Updated 8/01

INSTALLATION INSTRUCTIONS
IMPORTANT OPERATING CONDITIONS
Failure to comply with any of these conditions invalidates the warranty.
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 fluids cannot be
pumped unless approval in writing is obtained
before operation from Giant Industries, Inc.
4. Run the pump dry approximately 10 seconds
to drain the water before exposure to freezing
temperatures.
1. Prior to initial operation, Check for proper oil
level. DO NOT OVERFILL.
Use Giant Synthetic Oil
Crankcase oil should be changed after the
first 50 hours of operation, then at regular
intervals of 500 hours or less depending on
operating conditions.
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 instal-
lation. If you have unique requirements, please contact Giant Industries, Inc. or your local distributor
for assistance.
Finally,rememberthathighpressureoperationinapumpsystemhasmanyadvantages. But,ifitisusedcarelessly
and without regard to its potential hazard, it can cause serious injury.
NOTE: Contact Giant Industries for Service School Information. Phone: [phone]
1. For horizontal applications the pump should be
installed flat 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
flow rate of the pump with no unnecessary
restrictions that can cause cavitation. Teflon tape
should be used to seal all joints. Maximum inlet
fluid temperature is 80oF.
3. The discharge plumbing from the pump should
be properly sized to the flow 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
pressure spikes in the event of a blockage or the
use of a shut-off gun.
4. Use of a dampener is necessary to minimize
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 severity of pressure spikes that occur in systems
using a shut-off gun. A dampener must be positioned
downstream from the regulator.
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. Cavitation will result in severe
damage. Always remember to check that all plumb-
ing valves are open and that pumped media can flow
freely to the inlet of the pump.

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
Specifications
Model GXR Series
GXR2224..............................................................................................2.2 GPM @ 2400 PSI
GXR2424..............................................................................................2.4 GPM @ 2400 PSI
Maximum Inlet Pressure.......................................................................Up to 90 PSIG1
RPM......................................................................................................3450
Plunger Diameter..................................................................................16mm
Stroke GXR2224 ..................................................................................4.7mm (6.1 oangle)
Stroke GXR2424 ..................................................................................5.1mm (6.3 oangle)
Crankcase Oil Capacity ........................................................................4.7 fl. oz. (4.1 fl.oz. horizontal)
Temperature of Pumped Fluids ............................................................Up to 80 oF
Inlet Port ...............................................................................................1/2" NPT
Discharge Ports.....................................................................................3/8" NPT
Shaft Rotation.......................................................................................Either Direction2
Weight...................................................................................................9 lbs.
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
1A 25 PSIG minimum inlet pressure is required.
2The 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
approximately twice the pump
power requirements shown above.
We recommend a 1.15 service factor
be specified when selecting an
electric motor as the power source.
To 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 or
vertical orientation as well as by makes and
model from each manufacturer.
GXR2224 GAS ENGINE HORSEPOWER
REQUIREMENTS*
RPM GPM 1000 PSI 1500 PSI 2000 PSI 2500 PSI
3450 2.2 2.0 3.0 4.0 5.0
GXR2224 ELECTRIC HORSEPOWER
REQUIREMENTS
RPM GPM 1000 PSI 1500 PSI 2000 PSI 2500 PSI
3450 2.2 1.5 2.3 3.0 3.8

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

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"
(GXRH1114) 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 Orifice, 1.8mm 1
44A06339 Orifice, 2.1mm 1
44A06340 Orifice, 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

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, re-
move 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 flange
(39) and flange 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-
foldinthesamepositiondur-
ing reassembly.

Wobble
Pressure (in Thremal Plate
100 psi Relief Shaft
GX or HR Series Flow increments) Injector Size Valve Bore
Vertical 20=GPM 25=2500 PSI 1=2.1 mm 1=1/2" 1=3/4"
Horizontal 23=GPM 2=1.8mm 2=7/8"
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 Oriface, 1/2" thermal relief valve and 7/8" wobble plate bore.
GXR SERIES REPAIR INSTRUCTIONS
13. Reassemble in reverse order.
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
withascrewdriver. Take care
not to make contact with the
plunger (8) and pry out the
oil seals from their housing.
Seals should not be rein-
stalled until after step #16.
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

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. For portable pressure washers and self-service car wash applications, the discharge
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 five 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 manufacturer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 modifications made by the customer or third party.
6. The operation of pumps and or accessories exceeding the specifications 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
workmanship 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
warranty 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
hereunder and the MANUFACTURER SHALL NOT BE LIABLE FOR FURTHER LOSS, 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-
RANTIES OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE AND ALL SUCH
WARRANTIES ARE HEREBY DISCLAIMED AND EXCLUDED BY THE MANUFACTURER.
GXR Series
Dimensions
(inches)
GIANT INDUSTRIES, INC., 900 N. Westwood Ave., P.O. Box 3187, Toledo, Ohio
43607
PHONE [phone], FAX [phone], www.giantpumps.com
Ó Copyright 2001 Giant Industries, Inc. 08/2001 GXR.PM6