Giant HR3025 User's Manual
Contents
1. HR3030 2 enne en nn en en en en ee WR enn en en en ee CO en ee NPN ee HR2527A HR3025 HR3030 Repair Kits Unloader Repair Kit Plunger Packing Kit 09235 09465 oo Item Part Description Item Part Description Qty 07913 O Ring 22 06290 Pressure Ring 3 07937 O Ring Adjusting Screw 20 06315 V Sleeve 3 12031 0002 Teflon Back Up Ring 06227 Smm Ball 12007 O Ring 12326 O Ring 07935A By Pass Seat wenen Valve Assembly Kit Oil Seal Kit 09475 09468 Item Part Description Oty Item Part Description 18 07374 Valve Spring 6 15 06316 Plunger Oil Seal 3 19A 06267 Guided P Valve 3 19 06295 Discharge Valve Cone 3 HR2527A HR3025 HR3030 SERIES TORQUE SPECIFICATIONS Position Item Description Torque Amount ft Ibs 2 07881A Socket Head Cap Screw 1 4 100in lbs 39 06320 Stud Bolt 360in lbs GX and HR Pump Part Numbering System Thremal Relief Pressure in 100 psi GX or HR Series Flow increments Injector Size Valve tie ie ee 8 oma asem emm ier Oo oo eow emm o ler o o e T oan a la 50 o o 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 5 MALFUNCTION The Pressure and or the Delivery Drops Water in crankcase Noisy Operation Rough Pulsating Operation with Pressure Drop Pressure Drop at Gun Excessive Leakage High Crankcase T2. Maximum Inlet Pressure Plunger Diameter SNOKE naaa a a edd hae Sd ee eee deed 5 9mm 8 0 angle Crankcase Onl Capacity Sind a vereerden ebde 4 5 fl oz Temperature of Pumped Fluids Up to 80 F Inlet Port 1 x 1 2 NPT Discharge Ports 3 8 NPT Shaft Rotation Clockwise 11 4 Ibs 6 7 16 10 1 4 3 4 x 3 16 Keyway Polyamide Plastic 1 A 25 PSIG minimum inlet pressure is required HR3025 ELECTRIC HORSEPOWER HORSEPOWER RATINGS REQUIREMENTS The rating shown are the power requirements for the pump Gas 3450 engine power outputs must be approximately twice the pump power requirements shown above HR3025 GAS HORSEPOWER REQUIREMENTS 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 Specifications Model HR3030 Axial Pump Vol me PUR 090 ten acteurs a e tibet 3 0 GPM Maximum Discharge Pressure Maximum Inlet Pressure Plunger Diameter STORE terende eneen eeen 5 9mm 8 0 angle Crankcase Oil Capacity eeens erneener sneren eeneeneenennn 4 5 fl oz Temperature of Pumped Fluids Up to 80 F Inlet Port 1 x 1 2 NPT Discharge Ports 3 8 NPT Shaft Rotation Clockwise 11 4 Ibs 6 7 16 10 1 4 1 x3 16 Keyway Polyamide Plastic 1 A 25 PSIG minimum inlet pressure is required HR3030 ELECTRIC HORSEPOWER EE
3. Ses e rating shown are the power REQUIREMENTS requirements for the pump Gas engine power outputs must be 3450 ae ese HR3030 GAS HORSEPOWER requirements shown above REQUIREMENTS 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 w gt a Lu a O l a lt Lu o fe oc T LO N Q bd oc I lt N N LN N oc I aje q Buydepy OEOEHH ITEM PART 1 06311 1 06403 2 07881A 3 07344 4 07805 06419 06402 06393 06401 08089 06300 06301 06319 06318 06291 07873 06316 06317 07374 06295 06267 06315 06290 06424 07379 07913 06313 07910A 06320 08083 06273 08192 HR2527A HR3025 HR3030 SERIES PARTS LIST DESCRIPTION Adapting Plate HR2527A HR3025 Adapting Plate HR3030 Socket Head Cap Screw 17 O Ring Radial Shaft Seal 7 1 Piece Wobble Plate HR2527A 8 Wobble Plate HR3025 HR3030 Steel Shaft 4 HR2527A HR3025 Steel Shaft 1 HR3030 Crankcase Rear Bearing Complete Front Bearing Complete Plunger Spring Disc Retainer Clip Ring Plunger Spring Oil Seal Spacer Ring Valve Spring Valve Cone Discharge Valve Cone Inlet V Sleeve Pressure Ring Manifold Manifold Plug O Ring Suction Flange O Ring Flange Stud Bolt Oil Fill Cap Oil Drain Plug
4. pump s nonmetal parts elastomers from cutting and scoring Tap the back of the manifold 28 With a 19mm socket wrench remove the guide plug 54 and o ring 56 with arubber mallet to dislodge from the manifold 28 Remove the piston 46 o ring 47 and backup and slide off the plungers 10 rings 48 Using a 7 32 Allen wrench remove the bypass valve seat Take note of the position of the 66 Inspect the parts for wear and replace as necessary discharge port so as to place the port in the same position during reassembly Remove the valve cones 19A valve springs 18 v sleeves 20 and 10 Ifthe crankcase oil seals 15 pressure rings 22 Inspect for wear and replace as necessary are to be replaced they Remove the spacer ring 16 and flinger 56 from the plungers 10 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 Reassemble in reverse order Fill the crankcase until the proper amount of oil see specifications page 3 The pump is now ready for operation Contact Giant Industries for service school information Phone 419 531 4600 HR2527A HR3025 HR3030 o SERIES DIMENSIONS HR3030 ___ 9 75 HR2527A HR3025 GIANT INDUSTRIES LIMITED WARRANTY Giant Indu
5. Gasket QTY 1 1 8 1 1 1 1 1 1 1 1 1 3 3 3 3 3 3 6 3 3 3 3 1 3 1 1 1 3 1 1 1 ITEM 46 47 48 49 50 51 52 54 56 58 59 62 63 64 66 69 72 75 76 77 78 79 80 81 84 87 88 89 90 91 PART 06423 07937 12031 0002 06227 06324 07917A 06608 06239 12007 07045 06524 12326 12325 12328 07935A 06414 07467 06224 23422A 06306 12516 001 23010 0100 23009 06312 06339 12517 07044 07046 08250 07939 07068 09502 DESCRIPTION Piston O Ring Back Up Ring Ball By Pass Valve Adjusting Plug Washer Adjusting Spring Guide Plug O Ring Handwheel Adjusting Screw O Ring Kick Back Valve Cone Kick Back Valve Spring By Pass Valve Seat Mounting Flange X Style HR2527 Bolt HR2527 Washer Thermal Valve Injector Retainer O Ring Viton Ball 7 32 Dia ss Spring Injector O Ring Oriface 2 1mm Hose Barb Locknut Cover Sightglass w gasket Nut Locknut w Nylon Insert Gasoline Flange kit 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 amp 06301 HR2527A When ordering 06402 please order 17051 which includes 06402 06393 amp 06301 HR3025 When ordering 06402 please order 17040 which includes 06402 06401 amp 6301
6. Triplex Ceramic Plunger Pump Operating Instructions Models Ts HR2527A HR3025 HR3030 Pumps Consumer Pumps HR2527A shown Contents Installation Instructions page 2 Pump Specifications pages 3 5 Exploded View page 6 Parts List page 7 MADE IN THE USA Kits Torgue Specs page 8 a en Touble Shooting page 9 pr Repair Instructions page 10 11 Dimensions Warranty back page Updated 5 02 INSTALLATION INSTRUCTIONS 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 80 F 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 between the pump and the work area to protect the
7. emperature PUMP TROUBLE SHOOTING CAUSE Worn packing seals Broken valve spring Worn or Damaged nozzle Fouled discharge valve Fouledinlet strainer Worn or Damaged hose Worn or Plugged relief valve on pump Cavitation Highhunudity Worn seals Worn bearings Cavitation Worm packing Inletrestriction Cavitation Restricted discharge plumbing Wor plungers Worn packing seals Excessive vacuum Inlet pressure too high Wrong Grade of oil Improper amount of oil in crankcase REMEDY Replace packing seals Replace spring Replace nozzle Clean valve assembly Clean strainer Repair Replace hose Clean Reset andReplacewomparts Check suction lines oninlet of pump forrestrictions Reduce oil change interval Replace seals Replace bearings Refill crankcase oil withrecommendedlubricant Checkinlet lines forrestrictions and or proper sizing Replace packing Check system for stoppage air leaks correctly sized inlet plumb ing to pump Check inlet lines forrestrictions and or proper size Re size discharge plumbing to flowrate of pump Replace plungers Adjust or Replace packing seals Reduce suction vacuum Reduce imlet pressure Giant oil is recommended Adyust oil level to proper amount 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 protecti
8. ng the pump s nonmetal parts elastomers from cutting and scoring 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 A WME 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 3 With a crescent wrench remove the injector retainer 76 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 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 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 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
9. placement 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 419 531 6836 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 FURTHERLOSS 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 ORIMPLIED 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 GIANT INDUSTRIES INC 900 N Westwood Ave P O Box 3187 Toledo Ohio 43607 PHONE 419 531 4600 FAX 419 531 6836 www giantpumps com Copyright 2001 Giant Industries Inc 3 01 HR2527A HR3030 PM6
10. 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 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 IMPORTANT OPERATING CONDITIONS Failure to comply with any of these conditions invalidates the warranty 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 3 Acids alkalines or abrasi
11. stries 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 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 Normal wear and tear to standard wear parts Use of repair parts other than those manufactured or authorized by Giant Improper use of the product as a component part Changes or modifications made by the customer or third party 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 re
12. ve 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 NOTE Contact Giant Industries for Service School Information Phone 419 531 4600 Specifications Model HR2527A Axial Pump Volume HR252 TA neee eenen 2 5 GPM Maximum Discharge Pressure Maximum Inlet Pressure Plunger Diameter Stroke E E E EA ensen 5 3mm 7 1 angle Crankcase Qil Capacity sricecuiremeiesiene nein nn a 4 5 fl oz Temperature of Pumped Fluids Up to 80 F Inlet Port 1 x 1 2 NPT Discharge Ports 3 8 NPT Shaft Rotation Clockwise 11 7 lbs 12 7 lbs 6 9 16 7 25 32 3 4 x 3 16 Keyway Polyamide Plastic 1 A 25 PSIG minimum inlet pressure is required HR2527A ELECTRIC HORSEPOWER HORSEPOWER RATINGS The rating shown are the power REQUIREMENTS requirements for the pump Gas engine power outputs must be 3450 approximately twice the pump power requirements shown above HR2527A GAS HORSEPOWER REQUIREMENTS We recommend a 1 15 service factor be specified when selecting an 3450 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 Specifications Model HR3025 Axial Pump Volume HR3030 ssent keia e RR 3 0 GPM Maximum Discharge Pressure
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