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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