Giant GX Series, GX2525 Manual

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 installation. 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. Maximum inlet fluid temperature is 80 ºF.
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 pressure spikes in the event of a blockage or the use of a shut-off gun.
4. 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.

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.

IMPORTANT OPERATING CONDITION

Failure to comply with any of these conditions invalidates the warranty.

1. Prior to initial operation, Check for proper oil level. DO NOT OVERFILL.
   Use Giant Oil - P/N 01153 (20W-50 non-detergent motor oil)
   Crankcase oil should be changed after the first 50 hours of operation, then at regular intervals 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).
   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.

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 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 GX Series

¹ A 25 PSIG (2 Bar) 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 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 horsepower requirements, use the Following formula:
Electric HP = (GPM X PSI) / 1450
Gasoline HP = (GPM X PSI) / 1100

GX2525 ELECTRIC HORSEPOWER REQUIREMENTS

GX2525 GAS HORSEPOWER REQUIREMENTS

GX SERIES PARTS LIST

* When ordering 06310A, please order 17026A which includes 06300A, 07805, and 06294 ** When ordering 06331A, please order 17032A which includes 06331A, 06301A, and shaft ring.

*** Optional Non-Handle Model - (Item 23) o-ring p/n 12007, (Item 26) o-ring p/n 07937, (item 33) adjusting screw 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 cone p/n 12325 (item 43) kick back spring p/n 12328, (item 47) kick back valve retainer p/n 12340

+ When ordering 06326A, please order 17020A which includes 06326A, 06301A, and shaft ring.
++ When ordering 06419A, please order 17171A which includes 06419A, 06159A, and 06301A.

MOUNTING ACCESSORIES

(Sold Separately)

¹ "EX" Suffix added for engines requiring an external pilot

GX SERIES TORQUE SPECIFICATIONS

GX Series EXPLODED VIEW

Plunger Packing Kit # 09465

Valve Assembly Kit # 09466

Oil Seal Kit # 09468

Unloader Repair Kit # 09467

REPAIR INSTRUCTIONS - GX SERIES

1. With a 14mm socket wrench, remove the three discharge valve plugs (22). 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). Inspect the parts for wear and replace as necessary.
   
3. With a crescent wrench, remove the kickback valve spring retainer (47). Inspect the o-ring (46) for wear and replace as necessary. Remove the kickback valve spring (43), kickback valve cone (42), and the o-ring (41) from the manifold (35). Inspect the parts for wear and replace as necessary.
   
4. With a 19mm wrench, remove the adjusting screw plug (34). Unscrew the adjusting screw (33) from the adjusting screw plug (34). Inspect the o-rings (23 & 26) for wear and replace 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.
   Optional pump without handle - exclude items (52, 53, 54, 55, 56).
   
6. With a 14mm socket wrench, remove the guide plug (22) and o-ring (23).
7. Remove the piston (24), o-ring (26), and backup rings (25). Remove the bypass valve seat (28). Inspect the parts for wear and replace as necessary.
   
   Make sure that the shoulder on bypass valve seat (28) is facing the discharge plug (22).

GX2525 EXPLODED VIEW

8. Next, remove the four manifold 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 manifold in the same position during reassembly.
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 #13.
    

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.

GX Series Dimensions

inches (mm)

PHONE (419) 531-4600,
FAX (419) 531-6836,

www.giantpumps.com

Documents / Resources

References

• Giant Pumps

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