Giant Water Pump HR2527A User Manual

Triplex Ceramic  
Plunger Pump  
OperatingInstructions/  
Repair and Service  
Manual  
Models  
HR2527A/HR3025/  
HR3030 Pumps  
Consumer Pumps  
HR2527A shown  
Contents:  
InstallationInstructions: page 2  
Pump Specifications:  
Exploded View:  
pages 3-5  
page 6  
Parts List:  
page 7  
page 8  
page 9  
page 10-11  
back page  
MADE IN THE USA  
Kits/TorgueSpecs:  
ToubleShooting  
RepairInstructions:  
Dimensions/Warranty:  
Updated 5/02  
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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 o angle)  
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  
1
A 25 PSIG minimum inlet pressure is required.  
HORSEPOWER RATINGS:  
HR2527A ELECTRIC HORSEPOWER  
The rating shown are the power  
requirements for the pump. Gas  
engine power outputs must be  
approximately twice the pump  
REQUIREMENTS  
RPM GPM 1000 PSI 1500 PSI 2000 PSI 2750 PSI  
3450 2.5  
1.7  
2.6  
3.4  
4.7  
power requirements shown above.  
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  
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  
3
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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 o angle)  
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  
1
A 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.  
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  
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  
4
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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 o angle)  
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  
1
A 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.  
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  
HR3030 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:  
RPM GPM 1500 PSI 2000 PSI 2500 PSI 3000 PSI  
3450 3.0  
4.1  
5.5  
6.8  
8.2  
Electric HP = (GPM X PSI) / 1460  
Gas HP = (GPM X PSI) / 1100  
5
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HR2527A/HR3025/HR3030 EXPLODED VIEW  
6
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HR2527A/HR3025/HR3030 SERIES PARTS LIST  
ITEM PART #  
DESCRIPTION  
QTY.  
1
ITEM PART #  
DESCRIPTION  
Piston  
QTY.  
1
46  
47  
48  
49  
50  
51  
52  
54  
56  
58  
59  
62  
63  
64  
66  
06423  
07937  
1*  
1*  
2
06311  
06403  
07881A  
07344  
07805  
06419  
06402  
06393  
06401  
08089  
Adapting Plate (HR2527A/HR3025)  
Adapting Plate (HR3030)  
Socket Head Cap Screw ¼”  
O-Ring  
O-Ring  
2
1
12031-0002 Back-Up Ring  
Ball, By Pass Valve  
2
8
06227  
06324  
07917A  
06608  
06239  
12007  
07045  
06524  
12326  
12325  
12328  
07935A  
06414  
07467  
06224  
23422A  
06306  
1
3
1
Adjusting Plug  
Washer  
1
4
Radial Shaft Seal  
7.1o Piece Wobble Plate (HR2527A)  
8o Wobble Plate (HR3025/HR3030)  
Steel Shaft ¾” (HR2527A/HR3025)  
Steel Shaft 1" (HR3030)  
Crankcase  
1
1
5**  
5**  
6
1
Adjusting Spring  
Guide Plug  
1
1
1
1
O-Ring  
8
6
1
Handwheel  
1
7
1
Adjusting Screw  
O-Ring  
1
8A* 06300  
8B** 06301  
Rear Bearing, Complete  
Front Bearing, Complete  
Plunger  
1
1
1
Kick-Back Valve Cone  
Kick-Back Valve Spring  
By Pass Valve Seat  
Mounting Flange "X" Style (HR2527)  
Bolt(HR2527)  
1
10  
11  
12  
14  
15  
16  
18  
19  
19A  
20  
22  
28  
34  
36  
37  
38  
39  
41  
42  
43  
06319  
06318  
06291  
07873  
06316  
06317  
07374  
06295  
06267  
06315  
06290  
06424  
07379  
07913  
06313  
07910A  
06320  
08083  
06273  
08192  
3
1
Spring Disc Retainer  
Clip Ring  
3
1
3
67+  
1
Plunger Spring  
3
69  
72  
75  
76  
77  
78  
79  
80  
81  
84  
87  
88  
89  
90  
91  
+
4
Oil Seal  
3
Washer  
3
Spacer Ring  
3
Thermal Valve  
Injector Retainer  
1
Valve Spring  
6
1
Valve Cone (Discharge)  
Valve Cone (Inlet)  
V-Sleeve  
3
12516-001 O-Ring Viton  
1
3
23010-0100 Ball, 7/32” Dia. ss  
1
3
23009  
06312  
06339  
12517  
07044  
07046  
08250  
07939  
07068  
Spring, Injector  
O-Ring  
1
Pressure Ring  
3
1
Manifold  
1
Oriface, 2.1mm  
Hose Barb  
1
Manifold Plug  
3
1
O-Ring  
1
Locknut  
1
Suction Flange  
1
Cover  
1
O-Ring, Flange  
1
Sightglass w/gasket  
Nut  
1
Stud Bolt  
3
1
OilFillCap  
1
Locknut w/Nylon Insert  
1
Oil Drain Plug  
1
Gasket  
1
+
09502  
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, & 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  
7
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HR2527A/HR3025/HR3030 Repair Kits  
Unloader Repair Kit  
Plunger Packing Kit  
# 09235  
# 09465  
Item  
36  
47  
48  
49  
56  
62  
66  
Part #  
07913  
07937  
12031-0002  
06227  
12007  
12326  
07935A  
Description  
O-Ring  
O-Ring,Adjusting Screw  
Teflon Back-Up Ring  
8mm Ball  
O-Ring  
O-Ring  
By Pass Seat  
Qty.  
1
2
2
1
2
1
1
Item  
22  
Part # Description  
06290 Pressure Ring  
06315 V-Sleeve 3  
Qty.  
3
20  
Oil Seal Kit  
ValveAssembly Kit  
# 09468  
# 09475  
Item  
15  
Part #  
06316  
Description  
Plunger Oil Seal  
Qty.  
3
Item  
18  
Part # Description  
Qty.  
6
07374  
Valve Spring  
19A 06267  
19 06295  
Guided P-Valve  
DischargeValve Cone  
3
3
HR2527A/HR3025/HR3030 SERIES TORQUE SPECIFICATIONS  
Position  
Item#  
07881A  
06320  
Description  
Socket Head Cap Screw 1/4"  
Stud Bolt  
TorqueAmount (ft.-lbs)  
100in-lbs.  
2
39  
360in-lbs.  
GX and HR Pump Part Numbering System  
Wobble  
Plate  
Shaft  
Pressure (in  
100 psi  
Thremal  
Relief  
GX or HR Series  
Vertical  
Flow  
increments)  
Injector Size Valve  
Bore  
20=GPM  
23=GPM  
25=GPM  
25=2500 PSI  
1=2.1 mm  
2=1.8mm  
3=2.3mm  
1=1/2"  
1=3/4"  
2=7/8"  
3=1"  
4=5/8”  
1
Horizontal  
GX or HR  
2.5  
25  
-
1
1
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.  
8
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PUMPTROUBLESHOOTING  
MALFUNCTION  
REMEDY  
CAUSE  
Replacepackingseals  
Replacespring  
ThePressureand/or  
theDeliveryDrops  
Wornpackingseals  
Brokenvalvespring  
Replacenozzle  
Cleanvalveassembly  
Cleanstrainer  
WornorDamagednozzle  
Fouleddischargevalve  
Fouledinletstrainer  
Repair/Replacehose  
Clean,Reset,andReplacewornparts  
Checksuctionlinesoninletof  
pumpforrestrictions  
WornorDamagedhose  
WornorPluggedreliefvalveonpump  
Cavitation  
Reduceoilchangeinterval  
Replaceseals  
Waterincrankcase  
NoisyOperation  
Highhumidity  
Wornseals  
Replacebearings,Refillcrankcase  
oilwithrecommendedlubricant  
Checkinletlinesforrestrictions  
and/orpropersizing  
Wornbearings  
Cavitation  
Replacepacking  
Rough/Pulsating  
Operationwith  
PressureDrop  
Wornpacking  
Inletrestriction  
Checksystemforstoppage,air  
leaks,correctlysizedinletplumb-  
ingtopump  
Checkinletlinesforrestrictions  
and/orpropersize  
Cavitation  
PressureDropat  
Gun  
Re-sizedischargeplumbingto  
flowrateofpump  
Restricteddischargeplumbing  
ExcessiveLeakage  
Replaceplungers  
Wornplungers  
AdjustorReplacepackingseals  
Reducesuctionvacuum  
Reduceinletpressure  
Wornpacking/seals  
Excessivevacuum  
Inletpressuretoohigh  
HighCrankcase  
Temperature  
Giant oil is recommended  
Adjust oil level to proper amount  
Wrong Grade of oil  
Improper amount of oil in crankcase  
9
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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.  
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.  
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).  
36  
63  
62  
3. With a crescent wrench, remove  
64  
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.  
49  
51  
52  
59  
47  
56  
58  
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.  
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.  
10  
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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.  
54  
56  
48 47  
48  
46  
66  
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.  
74  
16  
22  
20  
18  
19A  
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.  
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.  
Contact Giant Industries for service school information. Phone: (419) 531-4600  
11  
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11.25”  
(HR3030)  
HR2527A/HR3025/HR3030  
SERIES DIMENSIONS  
9.75”  
(HR2527A/HR3025)  
6.44”  
GIANTINDUSTRIESLIMITEDWARRANTY  
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 (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 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,EXPRESSORIMPLIED,INCLUDINGWITHOUTLIMITATIONANYWARRAN-  
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  
Ó Copyright 2001 Giant Industries, Inc.  
3/01HR2527A/HR3030.PM6  
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