Consumer Pumps GXR 2224

TriplexPlunger PumpOperating Instructions/Repair Instructions ManualConsumer PumpHorizontal/Vertical Pumpwith built-in Regulator, Thermal Relief Valve and Siphon InjectorModelGXR SeriesContents:Installation Instructions: page 2Pump Specifications: page 3Exploded View/Kits: page 4Parts List: page 5Torque Specifications: page 5Repair Instructions: pages 6-7Dimensions: back page Warranty Information: back pageUpdated 10/09INSTALLATION INSTRUCTIONS4. 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 flow 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 fluids 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 first 50 hours of operation, then at regular inter-vals of 200 hours or less depending on operating conditions.Since it is difficult 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 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 restric-tions that can cause cavitation. Teflon tape should be used to seal all joints. Maximum inlet fluid tem-perature 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 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: (419)-531-46002GXR2424 GAS ENGINE HORSEPOWERREQUIREMENTS* RPM GPM 1000PSI 1500PSI 2000PSI 2400 PSI 3450 2.4 2.2 3.3 4.4 5.2GXR2424 ELECTRIC HORSEPOWERREQUIREMENTS RPM GPM 1000PSI 1500PSI 2000PSI 2400 PSI 3450 2.4 1.6 2.5 3.3 3.9SpecificationsModel GXR SeriesGXR2224 ..............................................................................................2.2 GPM (8.3 l/m) @ 2400 PSIGXR2424 ..............................................................................................2.4 GPM (9.1 l/m) @ 2400 PSIMaximum Inlet Pressure .......................................................................Up to 90 PSIG1 RPM ......................................................................................................3450Plunger Diameter .................................................................................. .63” (16mm)Stroke GXR2224 ...................................................................................4.7mm (6.1 o angle)Stroke GXR2424 ...................................................................................5.1mm (6.3 o angle)Crankcase Oil Capacity ........................................................................4.7 fl. oz. (4.1 fl.oz. horizontal)Temperature of Pumped Fluids .............................................................Up to 80 oF (26.6 OC)Inlet Port ...............................................................................................1/2” NPTDischarge Ports .....................................................................................3/8” NPT Shaft Rotation .......................................................................................Either Direction2Weight ...................................................................................................9 lbs. (4.1kg)Width ....................................................................................................8.325”Height ....................................................................................................6.45”Swash Plate Bore (Horizontal) .............................................................3/4” x 3/16” KeywaySwash Plate Bore (Vertical) ..................................................................7/8” x 3/16” KeywayValve 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 specified when selecting an elec-tric motor as the power source. To compute specific pump horsepower requirements, use the Following formula: Electric HP = (GPM X PSI) / 1450Gas HP = (GPM X PSI) / 1100* Engine power varies based on horizontal or vertical orientation as well as by makes and model from each manufacturer.3GXR SERIES EXPLODED VIEWPlunger Packing Kit# 09465Item Part # Description Qty. 20 06290 Support Ring 3 21 06315 V-Sleeve 3Valve Assembly Kit# 09466Item Part # Description Qty. 18 07374 Valve Spring 6 19 06267 Guided P-Valve 3 36 06295 Discharge Valve Cone 3Oil Seal Kit# 09468Item Part # Description Qty. 15 06316 Plunger Oil Seal 3Regulator Repair Kit# 09534Item 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 44A 06308 Orifice, 1.8mm 1 44A 06339 Orifice, 2.1mm 1 44A 06340 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 KitA = See pump numbering system page 75REPAIR INSTRUCTION - GXR SERIES1. 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 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-fold in the same position during reassembly.6GXR SERIES REPAIR INSTRUCTIONS13. 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: (419)-531-4600For 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 ShaftGX or HR Series Flow increments) Injector Size Valve BoreVertical 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 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 a 2.1mm Orifice, 1/2” thermal relief valve and 7/8” wobble plate bore.7GIANT INDUSTRIES LIMITED WARRANTyGiant 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 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 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 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 (419)-531-6836 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 SeriesDimensions(inches)10/09 GXR.PMD GIANT INDUSTRIES, INC., 900 N. Westwood Ave., P.O. Box 3187, Toledo, Ohio 43607PHONE (419) 531-4600, FAX (419) 531-6836, www.giantpumps.com? Copyright 2009 Giant Industries, Inc.