Giant HR2527A User manual

Triplex Ceramic
Plunger Pump
Operating Instructions/
Repair and Service
Manual
Consumer Pumps
Models
HR2527A/HR3025/
HR3030 Pumps
Contents:
Installation Instructions: page 2
Pump Specifications: pages 3-5
Exploded View: page 6
Parts List: page 7
Kits/Torgue Specs: page 8
Touble Shooting page 9
Repair Instructions: page 10-11
Dimensions/Warranty: back page
MADE IN THE USA
HR2527A shown
Updated 5/02

2
INSTALLATION INSTRUCTIONS
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. Reverse rotation may be safely achieved by
following a few guidelines available upon request
from Giant Industries, Inc. Required horsepower
for system operation can be obtained from the
charts on pages 3 and 6.
5. 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 plumbing valves are open and that
pumped media can flow freely to the inlet of the
pump.
NOTE: An anti-sieze material must be
applied to the engine cranckshaft to ensure
trouble free disassembly of the pump.
IMPORTANT OPERATING CONDITIONS
Failure to comply with any of these conditions invalidates the warranty.
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. 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.
Use Giant synthetic oil
2. Pump operation must not exceed rated
pressure, volume, or RPM. A pressure relief
device must be installed in the discharge of the
system.
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 installa-
tion. If you have unique requirements,
please contact Giant Industries, Inc. or your
local distributor for assistance.
1. 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. If pumps
are to be operated at temperatures in excess of
800F, it is important to insure a positive head to
the pump to prevent cavitation.
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
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]

HR2527A ELECTRIC HORSEPOWER
REQUIREMENTS
RPM GPM 1000 PSI 1500 PSI 2000 PSI 2750 PSI
3450 2.5 1.7 2.6 3.4 4.7
3
Specifications
Model HR2527A
Axial Pump
Volume HR2527A .................................................................................2.5 GPM
Maximum Discharge Pressure .............................................................2750 PSI
Maximum Inlet Pressure ...................................................................... Up to 90 PSIG1
RPM .....................................................................................................3450
Plunger Diameter ..................................................................................16mm
Stroke ....................................................................................................5.3mm (7.1 oangle)
Crankcase Oil Capacity ........................................................................4.5 fl. oz.
Temperature of Pumped Fluids .............................................................Up to 80 oF
Inlet Port ...............................................................................................1 x 1/2" NPT
Discharge Ports ....................................................................................3/8" NPT
Shaft Rotation .......................................................................................Clockwise
Weight ...................................................................................................11.7 lbs. (12.7 lbs.)
Width .....................................................................................................6-9/16"
Height ...................................................................................................7-25/32"
Swash Plate Bore .................................................................................3/4" x 3/16" Keyway
Valve Type ............................................................................................Polyamide Plastic
1A 25 PSIG minimum inlet pressure is required.
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
HR2527A GAS HORSEPOWER
REQUIREMENTS
RPM GPM 1000 PSI 1500 PSI 2000 PSI 2750 PSI
3450 2.5 2.3 3.4 4.5 6.3

Specifications
Model HR3025
Axial Pump
Volume HR3030....................................................................................3.0 GPM
Maximum Discharge Pressure .............................................................2500 PSI
Maximum Inlet Pressure ...................................................................... Up to 90 PSIG1
RPM .....................................................................................................3450
Plunger Diameter ..................................................................................16mm
Stroke ....................................................................................................5.9mm (8.0 oangle)
Crankcase Oil Capacity ........................................................................4.5 fl. oz.
Temperature of Pumped Fluids .............................................................Up to 80 oF
Inlet Port ...............................................................................................1 x 1/2" NPT
Discharge Ports ....................................................................................3/8" NPT
Shaft Rotation .......................................................................................Clockwise
Weight ...................................................................................................11.4 lbs.
Width .....................................................................................................6-7/16"
Height ...................................................................................................10-1/4"
Swash Plate Bore .................................................................................3/4 x 3/16 Keyway
Valve Type ............................................................................................Polyamide Plastic
1A 25 PSIG minimum inlet pressure is required.
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
HR3025 ELECTRIC HORSEPOWER
REQUIREMENTS
RPM GPM 1000 PSI 1500 PSI 2000 PSI 2500 PSI
3450 3.0 2.1 3.1 4.1 5.1
HR3025 GAS HORSEPOWER
REQUIREMENTS
RPM GPM 1000 PSI 1500 PSI 2000 PSI 2500 PSI
3450 3.0 2.7 4.1 5.5 6.8
4

HR3030 ELECTRIC HORSEPOWER
REQUIREMENTS
RPM GPM 1500 PSI 2000 PSI 2500 PSI 3000 PSI
3450 3.0 3.1 4.1 5.1 6.2
Specifications
Model HR3030
Axial Pump
Volume HR3030....................................................................................3.0 GPM
Maximum Discharge Pressure .............................................................3000 PSI
Maximum Inlet Pressure ...................................................................... Up to 90 PSIG1
RPM .....................................................................................................3450
Plunger Diameter ..................................................................................16mm
Stroke ....................................................................................................5.9mm (8.0 oangle)
Crankcase Oil Capacity ........................................................................4.5 fl. oz.
Temperature of Pumped Fluids .............................................................Up to 80 oF
Inlet Port ...............................................................................................1 x 1/2" NPT
Discharge Ports ....................................................................................3/8" NPT
Shaft Rotation .......................................................................................Clockwise
Weight ...................................................................................................11.4 lbs.
Width ..................................................................................................... 6-7/16"
Height ...................................................................................................10-1/4"
Swash Plate Bore ................................................................................. 1"x3/16" Keyway
Valve Type ............................................................................................Polyamide Plastic
1A 25 PSIG minimum inlet pressure is required.
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
HR3030 GAS HORSEPOWER
REQUIREMENTS
RPM GPM 1500 PSI 2000 PSI 2500 PSI 3000 PSI
3450 3.0 4.1 5.5 6.8 8.2
5

6
HR2527A/HR3025/HR3030 EXPLODED VIEW

7
HR2527A/HR3025/HR3030 SERIES PARTS LIST
* When ordering a 06311 please order 17021 which includes 06311, 07344, 07805, 06300 - HR2527A/HR3025
* When ordering a 06403, please order 17038 which includes 06403, 07344, 07805, 06300 - HR3030
** When ordering 06419, please order 17036, which includes 06419, 06393, & 06301 - HR2527A
** When ordering 06402, please order 17051, which includes 06402, 06393 & 06301 - HR3025
** When ordering 06402, please order 17040, which includes 06402, 06401, & 6301 - HR3030
ITEM PART # DESCRIPTION QTY.
1 * 06311 Adapting Plate (HR2527A/HR3025) 1
1 * 06403 Adapting Plate (HR3030) 1
2 07881A Socket Head Cap Screw ¼ 8
3 07344 O-Ring 1
4 07805 Radial Shaft Seal 1
5 * * 06419 7.1
o
Piece Wobble Plate (HR2527A) 1
5 * * 06402 8
o
Wobble Plate (HR3025/HR3030) 1
6 06393 Steel Shaft ¾ (HR2527A/HR3025) 1
6 06401 Steel Shaft 1" (HR3030) 1
7 08089 Crankcase 1
8 A * 06300 Rear Bearing, Complete 1
8B** 06301 Front Bearing, Complete 1
10 06319 Plunger 3
11 06318 Spring Disc Retainer 3
12 06291 Clip Ring 3
14 07873 Plunger Spring 3
15 06316 Oil Seal 3
16 06317 Spacer Ring 3
18 07374 Valve Spring 6
19 06295 Valve Cone (Discharge) 3
19A 06267 Valve Cone (Inlet) 3
20 06315 V-Sleeve 3
22 06290 Pressure Ring 3
28 06424 Manifold 1
34 07379 Manifold Plug 3
36 07913 O-Ring 1
37 06313 Suction Flange 1
38 07910A O-Ring, Flange 1
39 06320 Stud Bolt 3
41 08083 Oil Fill Cap 1
42 06273 Oil Drain Plug 1
43 08192 Gasket 1
+09502 Gasoline Flange kit
ITEM PART # DESCRIPTION QTY.
46 06423 Piston 1
47 07937 O-Ring 2
48 12031-0002 Back-Up Ring 2
49 06227 Ball, By Pass Valve 1
50 06324 Adjusting Plug 1
51 07917A Washer 1
52 06608 Adjusting Spring 1
54 06239 Guide Plug 1
56 12007 O-Ring 8
58 07045 Handwheel 1
59 06524 Adjusting Screw 1
62 12326 O-Ring 1
63 12325 Kick-Back Valve Cone 1
64 12328 Kick-Back Valve Spring 1
66 07935A By Pass Valve Seat 1
67 + 06414 Mounting Flange "X" Style (HR2527) 1
69 + 07467 Bolt (HR2527) 4
72 06224 Washer 3
75 23422A Thermal Valve 1
76 06306 Injector Retainer 1
77 12516-001 O-Ring Viton 1
78 23010-0100 Ball, 7/32 Dia. ss 1
79 23009 Spring, Injector 1
80 06312 O-Ring 1
81 06339 Oriface, 2.1mm 1
84 12517 Hose Barb 1
87 07044 Locknut 1
88 07046 Cover 1
89 08250 Sightglass w/gasket 1
90 07939 N u t 1
91 07068 Locknut w/Nylon Insert 1

Plunger Packing Kit
# 09465
Item Part # Description Qty.
22 06290 Pressure Ring 3
20 06315 V-Sleeve 3
Valve Assembly Kit
# 09475
Item Part # Description Qty.
18 07374 Valve Spring 6
19A 06267 Guided P-Valve 3
19 06295 Discharge Valve Cone 3
8
Position Item# Description Torque Amount (ft.-lbs)
2 07881A Socket Head Cap Screw 1/4" 100in-lbs.
39 06320 Stud Bolt 360in-lbs.
HR2527A/HR3025/HR3030 SERIES TORQUE SPECIFICATIONS
Unloader Repair Kit
# 09235
Item Part # Description Qty.
36 07913 O-Ring 1
47 07937 O-Ring,Adjusting Screw 2
48 12031-0002 Teflon Back-Up Ring 2
49 06227 8mm Ball 1
56 12007 O-Ring 2
62 12326 O-Ring 1
66 07935A By Pass Seat 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.
Oil Seal Kit
# 09468
Item Part # Description Qty.
15 06316 Plunger Oil Seal 3
HR2527A/HR3025/HR3030 Repair Kits
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

9
PUMP TROUBLE SHOOTING
MALFUNCTION
The Pressure and/or
theDelivery Drops
Waterin crankcase
Noisy Operation
Rough/Pulsating
Operationwith
Pressure Drop
Pressure Drop at
Gun
ExcessiveLeakage
HighCrankcase
Temperature
CAUSE
Worn packing seals
Brokenvalve spring
Worn or Damaged nozzle
Fouleddischarge valve
Fouledinletstrainer
Worn or Damaged hose
Worn or Plugged relief valve on pump
Cavitation
Highhumidity
Worn seals
Wornbearings
Cavitation
Wornpacking
Inletrestriction
Cavitation
Restricteddischargeplumbing
Wornplungers
Wornpacking/seals
Excessivevacuum
Inletpressure too high
Wrong Grade of oil
Improper amount of oil in crankcase
REMEDY
Replacepacking seals
Replacespring
Replacenozzle
Cleanvalveassembly
Cleanstrainer
Repair/Replacehose
Clean,Reset,andReplacewornparts
Checksuction lines on inlet of
pumpfor restrictions
Reduceoilchange interval
Replaceseals
Replacebearings,Refillcrankcase
oilwithrecommendedlubricant
Checkinlet lines forrestrictions
and/orproper sizing
Replacepacking
Check system for stoppage, air
leaks,correctly sized inlet plumb-
ing to pump
Checkinlet lines forrestrictions
and/or proper size
Re-sizedischarge plumbingto
flow rate of pump
Replaceplungers
Adjust or Replace packing seals
Reducesuctionvacuum
Reduceinlet pressure
Giant oil is recommended
Adjust oil level to proper amount

10
REPAIR INSTRUCTIONS - HR2527A/HR3025/HR3030
1. With a 19mm socket wrench, remove the three discharge valve plugs
(34). Inspect the valve plug o-rings (56) for wear, and replace as neces-
sary. Remove the valve spring (18) and valve cone (19) from the manifold
(28). Inspect the parts for wear and replace as necessary.
NOTE: Always take time to lubricate all metal and nonmetal parts with a light film of oil before reassembly. This step will ensure
proper fit, at the same time protecting the pump's nonmetal parts (elastomers) from cutting and scoring.
2. With a 19mm crescent wrench,
remove the adjusting screw as-
sembly (50, 56, 47, and 59).
Unscrew the adjusting screw
(59) from the adjusting screw
plug (50).
6. Next, remove the three manifold
stud nuts (39) with a 17mm
wrench. Remove the suction
flange (37) and flange o-ring
(38). Inspect the o-ring for wear
and replace as necessary.
5. Inspect the o-rings (56 and 47) for wear and replace as necessary.
Remove the adjusting spring (52), washer (51) and by pass valve ball
(49) from the manifold (28). Inspect the parts for wear and replace
as necessary.
49 51 52 59 47 56 58
4. Inspect the o-ring (36) for wear and replace as necessary.
Remove the kickback valve spring (64), kickback valve cone
(63), and the o-ring (62) from the manifold (28). Inspect and
clean the siphon injector and ball clean parts for wear and
replace as necessary.
3. With a crescent wrench, remove
the injector retainer (76).
36
64
63
62

11
7. Tap the back of the manifold (28)
with a rubber mallet to dislodge,
and slide off the plungers (10).
Take note of the position of the
discharge port so as to place the
port in the same position during
reassembly.
8. With a 19mm socket wrench, remove the guide plug (54) and o-ring (56)
from the manifold (28). Remove the piston (46), o-ring (47), and backup
rings (48). Using a 7/32" Allen wrench, remove the bypass valve seat
(66). Inspect the parts for wear and replace as necessary.
54 56 48 47 48 46 66
REPAIR INSTRUCTIONS - HR2527A/HR3025/HR3030
NOTE: Always take time to lubricate all metal and nonmetal parts with a light film of oil before reassembly. This step will ensure proper fit, at
the same time protecting the pump's nonmetal parts (elastomers) from cutting and scoring.
9. Remove the valve cones (19A), valve springs (18), v-sleeves (20) and
pressure rings (22). Inspect for wear and replace as necessary.
Remove the spacer ring (16) and flinger (56) from the plungers (10).
10. If the crankcase oil seals (15)
are to be replaced, they
can be removed by prying
loose with a small screwdriver.
Take care not to make contact
with the plunger (10) and pry
out the oil seals from their
housing.
74 16 22 20 18 19A
Contact Giant Industries for service school information. Phone: [phone]
11. Reassemble in reverse order.
Fill the crankcase until the
proper amount of oil (see
specifications page 3).
The pump is now ready for
operation.

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. A complete copy of our current RGA policy may be obtained from Giant Industries by written
request.
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 WARRAN-
TIES OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE AND ALL SUCH
WARRANTIES ARE HEREBY DISCLAIMED AND EXCLUDED BY THE MANUFACTURER.
HR2527A/HR3025/HR3030
SERIES DIMENSIONS
3/01 HR2527A/HR3030.PM6
6.44
9.75
(HR2527A/HR3025)
11.25
(HR3030)
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.