Consumer Pumps GX 2424

TriplexPlunger PumpOperating Instructions/Repair InstructionsManualConsumer PumpHorizontal/Vertical Pumpwith built-in ThermalRelief Valve and SiphonInjectorModelGX SeriesContents:Installation Instructions: page 2Pump Specifications: page 3Exploded View/Kits: page 4Torque Specifications: page 5Repair Instructions: pages 6-7Dimensions: back pageWarranty Information: back pageUpdated 10/09????????? ????INSTALLATION INSTRUCTIONS4. Use of a dampener is necessary to mini-mize pulsation at drive elements, plumbing,connections, and other system areas. Theuse of a dampener with Giant Industries, Inc.pumps is optional, although recommended byGiant Industries, Inc. to further reduce systempulsation. Dampeners can also reduce theseverity of pressure spikes that occur insystems using a shut-off gun. A dampenermust be positioned downstream from theunloader.6. Before beginning operation of your pumpingsystem, remember: Check that the crankcaseand seal areas have been properly lubricatedper recommended schedules. Do not run thepump dry for extended periods of time. Cavita-tion will result in severe damage. Alwaysremember to check that all plumbing valves areopen and that pumped media can flow freely tothe inlet of the pump.IMPORTANT OPERATING CONDITIONFailure to comply with any of these conditions invalidates the warranty.If everything looks okay, continue to usethe pump. At least once per year (or every 200hours), remove the oil from the pump andreplace with the required amount of oil. (Seepage 3)2. Pump operation must not exceed ratedpressure, volume, or RPM. A pressure reliefdevice must be installed in the discharge of thesystem.3. Acids, alkalines, or abrasive fluids cannotbe 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 tofreezing temperatures.1. Prior to initial operation, Check for proper oillevel. DO NOT OVERFILL.Use Giant Oil - P/N 01153(20W-50 Synthetic)Crankcase oil should be changed after thefirst 50 hours of operation, then at regular inter-vals of 200 hours or less depending on operatingconditions.Since it is difficult to determine the oil level inthe pump, check for signs of of oil leakage aroundthe pump before and during operation. The bestareas to check are between the manifold and thecrankcase and between the adapting plate andthe engine / motor mounting surface. Lastly, youcan see if there is any leakage around the ventcap (on the top of the pump).Installation of the Giant Industries, Inc., pumpis not a complicated procedure, but there aresome basic steps common to all pumps. Thefollowing information is to be considered as ageneral outline for installation. If you haveunique requirements, please contact GiantIndustries, Inc. or your local distributor forassistance.1. The pump should be installed flat on a base to amaximum of a 15 degree angle of inclination toensure optimum lubrication.2. The inlet to the pump should be sized for theflow rate of the pump with no unnecessary restric-tions that can cause cavitation. Teflon tape shouldbe used to seal all joints. Maximum inlet fluidtemperature is 80oF.3. 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 from pres-sure spikes in the event of a blockage or the use ofa shut-off gun.Finally, remember that high pressure operation in a pump system has many advantages. But, ifit is used carelessly and without regard to its potential hazard, it can cause serious injury.NOTE: Contact Giant Industries for Service School Information. Phone: (419)-531-46002SpecificationsModel GX SeriesU.S. (Metric)Flow ..........................................................................2.5 GPM ............. (9.5 LPM)Maximum Discharge Pressure .................................2500 PSI ............. (172 bar)Maximum Inlet Pressure...........................................Up to 90 PSIG1 ...... 6.2 Bar1Pump Speed .......................................................................................... 3450 RPMPlunger Diameter ......................................................4.23” .................... 16mmStroke .................................................................................................... 5.1mm (7.1o angle)Crankcase Oil Capacity (Horizontal) .......................4.1 fl.oz. .............. (121 ml )Crankcase Oil Capacity (Vertical) ............................4.7 fl. oz. ............. (138 ml)Temperature of Pumped Fluids ................................Up to 80 oF .......... (27 oC)Inlet Port ................................................................................................ 1/2" NPTDischarge Port ...................................................................................... 3/8" NPTShaft Rotation ........................................................................................ Either Direction2Weight ......................................................................9 lbs. ................... (4.1 Kg)Width ........................................................................8.325" .................. (21.15cm)Height .......................................................................6.45" .................... (16.4cm)Swash Plate Bore (Horizontal) .............................................................. 3/4" x 3/16" KeywaySwash Plate Bore (Vertical) .................................................................. 7/8" x 3/16" KeywayValve Type ............................................................................................ Polyamide Plastic1 A 25 PSIG (2 Bar) minimum inlet pressure is required.2 The pump itself can be driven in either direction of rotation; however, the coolingfan on TEFC motors must always be positioned so that the cooling air is drawnfrom the non-drive end of the motor towards the pump.HORSEPOWER RATINGS:The rating shown are the powerrequirements for the pump. Gasengine power outputs must beapproximately twice the pumppower requirements shown above.We recommend a 1.15 service factorbe specified when selecting anelectric motor as the power source.To compute specific pump horse-power requirements, use theFollowing formula:Electric HP = (GPM X PSI) / 1450Gasoline HP = (GPM X PSI) / 11003GX2525 GAS HORSEPOWER REQUIREMENTSRPM GPM 1000 PSI 1500 PSI 2000 PSI 2500 PSI3450 2.5 2.3 3.4 4.5 5.7GX2525 ELECTRIC HORSEPOWER REQUIREMENTSRPM GPM 1000 PSI 1500 PSI 2000 PSI 2500 PSI3450 2.5 1.7 2.6 3.4 4.3ITEM# Part# Description QTY.1 07805 Radial Shaft Seal 12 06310A Adapting Flange 13 06294 O-Ring (86 x 2.5mm) 14 06300 Rear Bearing 15 06326 Wobble plate 7.1 degreehorizontal, 3/4" 15 06331 Wobble plate 7.1 degreevertical, 7/8" 15 06419 Two-piece wobble plate,7.1 degree,(GXH2525A only) 15A 06159 Steel Shaft (for 06419) 16 06301 Front Bearing 17 06289 Spring Disk 38 06287 16mm Plunger 39 06288 Plunger Spring 310 06299 Socket Bolt 6(1/4-20x3/4 10.9 GRD)11 08192 Gasket 112 06273 Oil Drain Plug 113 06282 Crankcase 114 08083 Vent Cap, (Horizontal Only) 115 06316 16mm Oil Seal 317 06292 Spacer 318 07374 Valve Spring 619 06267 Guided P-Valve 320 06290 Pressure Ring 321 06315 16mm V-Sleeve 322 06296 Discharge Plug 423*** 12007 O-Ring 524 06304 Piston 125 12031-0002 Back-up ring 226*** 07937 O-Ring 227 08638 O-Ring of Push Seat 128 06256 Push in Seat 1GX SERIES PARTS LISTPosition Item# Description Torque Amount (ft.-lbs)10 06299 Socket Bolt 100 in.-lbs.40 06302 Stud Bolt 150 in.-lbs.GX SERIES TORQUE SPECIFICATIONS* When ordering 06310A, please order 17026A which includes 06300, 07805, and 06294** When ordering 06331, please order 17032 which includes 06331, 06301, and shaft ring.*** Optional Non-Handle Model - (Item 23) o-ring p/n 12007, (Item 26) o-ring p/n 07937, (item 33) adjustingscrew p/n 06323, (item 34) adjusting screw plug p/n 06324**** Optional Non-Injector Model - (item 41) kick back valve o-ring p/n 12326, (item 42) kick back valve conep/n 12325 (item 43) kick back spring p/n 12328, (item 47) kick back valve retainer p/n 12340+ When ordering 06326, please order 17020 which includes 06326, 06301, and shaft ring.++ When ordering 06419, please order 17171 which includes 06419, 06159, and 06301.MOUNTING ACCESSORIES (Sold Separately)Item Description09103(EX)1 Gasoline Flange Kit (excluding GXH2525A models)09605 Gasoline Flange Kit (GXH2525A only)07435 Bolts for 09103/096051 "EX" Suffix added for engines requiring an external pilotITEM# Part# Description QTY.29 06227 8mm Ball 130 07917A Washer 131 07918A Adjusting Spring 132 07919 Pressure Spring 133*** 06524 Adjusting Screw 134*** 06324 Adjusting Screw Plug 135 06286 Manifold 136 06295 Discharge Valve Cone 338 07910A Triangle O-Ring 139 06298 Suction Flange 140 06302 Stud Bolt(M8x1.25x50mm) 441**** 12326 Kick Back O-Ring 142**** 12325 Kick Back Valve Cone 143**** 12328 Kick Back Spring 144A 06727 Oriface, 1.8mm 144A 06339 Oriface, 2.1mm 144A 06340 Oriface, 2.3mm 145 06312 O-Ring in Nozzle 146 07913 O-Ring 147**** 06303 Injector Retainer 148 23009 Spring 149 23010-0100 Ball 150 12516-0001 O-Ring 151 12517 Hose Barb 152 07939 Nut 153 07044 Locknut 154 07045 Handwheel 155 07068 Locking Nut W/Nylon Insert 156 07046 Cover 175 23422A Thermal Relief Valve(Horizontal Pumps) 175 23422A-N Thermal Relief Valve(Vertical Pumps) 1A = See pump numbering system on page 7.4GX Series EXPLODED VIEWPlunger Packing Kit# 09465Item Part # Description Qty.20 06290 Support Ring 321 06315 V-Sleeve 3Valve Assembly Kit# 09466Item Part # Description Qty.18 07374 Valve Spring 619 06267 Guided P-Valve 336 06295 Discharge Valve Cone 3Oil Seal Kit# 09468Item Part # Description Qty.15 06316 Plunger Oil Seal 3Unloader Repair Kit# 09467Item Part # Description Qty.23 12007 O-Ring 225 12031-0002 Back-up Ring 226 07937 O-Ring 227 08638 O-Ring 128 06256 Seat 129 06227 8mm Ball 141 12326 O-Ring 15REPAIR INSTRUCTIONS - GX SERIES1. With a 14mm socketwrench, remove the threedischarge valve plugs(22). Inspect the valveplug o-rings (23) for wear,and replace as necessary.2. Remove the valve spring(18) and valve cone (36)from the manifold (35).Inspect the parts for wearand replace as neces-sary.3. With a crescent wrench,remove the kickbackvalve spring retainer (47).Inspect the o-ring (46) forwear and replace as nec-essary. Remove the kick-back valve spring (43),kickback valve cone (42),and the o-ring (41) from themanifold (35). Inspect theparts for wear and replaceas necessary.4. With a 19mm wrench, re-move the adjusting screwplug (34). Unscrew theadjusting screw (33) fromthe adjusting screw plug(34). Inspect the o-rings(23 & 26) for wear and re-place as necessary.5. Remove the adjusting spring (31), pressure spring (32),washer (30) and by pass valve ball (29) from the manifold(35). Inspect the parts for wear and replace as necessary.7. Remove the piston (24), o-ring (26), and backup rings (25). Re-move the bypass valve seat (28). Inspect the parts for wearand replace as necessary. IMPORTANT Make sure that theshoulder on bypass valve seat (28) is facing the dischargeplug (22).28 24 25 26 256. With a 14mm socketwrench, remove the guideplug (22) and o-ring (23). 29 30 32 31 33 26 23 34 52 53 54 55 56Optional pump without handle - excludeitems (52, 53, 54, 55, 56).27 23 226WobblePressure (in Thermal Plate100 psi Relief ShaftGX or HR Series Flow increments) Injector Size Valve BoreVertical 20=GPM 25=2500 PSI 1=2.1 mm 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 1GX and HR Pump Part Numbering SystemFor example, a GXV2525-112 is a GX pump that produces 2.5 GPM @ 2500 PSI, has a injector with a2.1mm Oriface, 1/2" thermal relief valve and 7/8" wobble plate bore.8. Next, remove the fourmanifold bolts (40) with a6mm allen wrench.9. Remove the suctionflange (39) and flange o-ring (38). Inspect the o-ring for wear and replaceas necessary.10. Tap the back of the mani-fold (35) with a rubber mal-let to dislodge, and slide offthe plungers. (8). Take noteof the position of the dis-charge port so as to placethe manifold in the sameposition during reassem-bly.GX2525 EXPLODED VIEW13. Reassemble in reverse or-der. Fill the crankcase withthe proper amount of oil(see specifications page 3)The pump is now ready foroperation.11. Remove the guided p-valve, (19), valve springs (18), v-sleeves (21) and pressure rings (20). Inspect for wear andreplace as necessary. Remove the spacer ring (17) fromthe plungers (8).12. If the crankcase oil seals(15) are to be replaced,they can be removed byprying loose with a screw-driver. Take care not tomake contact with theplunger (8) and pry out theoil seals from their hous-ing. Seals should not bereinstalled until after step#16.21 20 19 18 177GIANT INDUSTRIES LIMITED WARRANTYGiant 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 waterapplications.2. One (1) year from the date of shipment for all other Giant industrial and consumerpumps.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 themanufacturer’s evaluation shows were defective at the time of shipment by the manufacturer. Thefollowing 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 forthin 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 thoseproducts returned freight prepaid to Giant Industries which are deemed to be defective due toworkmanship or failure of material. A Returned Goods Authorization (R.G.A.) number andcompleted warranty evaluation form is required prior to the return to Giant Industries of all productsunder warranty consideration. Call (419)-531-4600 or fax (419)-531-6836 to obtain an R.G.A.number.Repair or replacement of defective products as provided is the sole and exclusive remedy providedhereunder and the MANUFACTURER SHALL NOT BE LIABLE FOR FURTHER LOSS, DAMAGES,OR EXPENSES, INCLUDING INCIDENTAL AND CONSEQUENTIAL DAMAGES DIRECTLY ORINDIRECTLY ARISING FROM THE SALE OR USE OF THIS PRODUCT.THE LIMITED WARRANTY SET FORTH HEREIN IS IN LIEU OF ALL OTHER WARRANTIES ORREPRESENTATION, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION ANY WARRAN-TIES OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE AND ALL SUCHWARRANTIES ARE HEREBY DISCLAIMED AND EXCLUDED BY THE MANUFACTURER.GX SeriesDimensionsinches (mm)10/09 GX2525.PMDGIANT INDUSTRIES, INC., 900 N. Westwood Ave., P.O. Box 3187, Toledo, Ohio43607 PHONE (419) 531-4600, FAX (419) 531-6836, www.giantpumps.com? Copyright 2009 Giant Industries, Inc.