Bentonite Pumps BP5236

Triplex CeramicPlunger PumpOperating Instructions/Repair and ServiceManualContents:Installation Instructions: page 2Pump Specifications: page 3Exploded View: page 4Parts List: page 5Kit List/TorqueSpecifications: page 6Recommended SpareParts List: page 6Repair Instructions: pages 7-9Pump Mounting Selection Guide: page 9Trouble Shooting: page10Dimensions: page 11Warranty Information: back pageModelBP52362NOTE: Contact Giant Industries for Service School Information. Phone: (419)-531-4600INSTALLATION INSTRUCTIONSInstallation of the Giant Industries, Inc., pump is not acomplicated procedure, but there are some basic stepscommon to all pumps. The following information is tobe considered as a general outline for installation. Ifyou have unique requirements, please contact GiantIndustries, Inc. or your local distributor for assistance.1. The pump should be installed flat on a base to amaximum of a 15 degree angle of inclination to ensureoptimum lubrication.2. The inlet to the pump should be sized for the flow rateof the pump with no unnecessary restrictions that cancause cavitation. Teflon tape should be used to seal alljoints. If pumps are to be operated at temperatures inexcess of 1600 F, it is important to insure a positive headto the pump to prevent cavitation. See NPSH curve.3. The discharge plumbing from the pump should beproperly sized to the flow rate to prevent line pressure lossto the work area. It is essential to provide a safety bypassvalve between the pump and the work area to protect thepump from pressure spikes in the event of a blockage or theuse of a shut-off gun.IMPORTANT OPERATING CONDITIONSFailure to comply with any of these conditions invalidates the warranty.1. Prior to initial operation, add oil to the crankcase so thatoil level is between the two lines on the oil dipstick. DONOT OVERFILL.Giant Oil RecommendedCrankcase oil should be changed after the first 50hours of operation, then at regular intervals of 500 hours orless depending on operating conditions.4. Use of a dampener is necessary to minimize pulsation atdrive elements, plumbing, connections, and other systemareas. The use of a dampener with Giant Industries, Inc.pumps is optional, although recommended by GiantIndustries, Inc. to further reduce system pulsation.Dampeners can also reduce the severity of pressure spikesthat occur in systems using a shut-off gun. A dampenermust be positioned downstream from the unloader.5. Crankshaft rotation on Giant Industries, Inc. pumpsshould be made in the direction designated by the arrows onthe pump crankcase. Reverse rotation may be safelyachieved by following a few guidelines available uponrequest from Giant Industries, Inc. Required horsepowerfor system operation can be obtained from the charts onpages 3.6. Before beginning operation of your pumping system,remember: Check that the crankcase and seal areas havebeen properly lubricated per recommended schedules. Donot run the pump dry for extended periods of time.Cavitation will result in severe damage. Always rememberto check that all plumbing valves are open and that pumpedmedia can flow freely to the inlet of the pump.2. Pump operation must not exceed rated pressure, volume,or RPM. A pressure relief device must be installed in thedischarge of the system.3. Acids, alkalines, or abrasive fluids cannot be pumpedunless approval in writing is obtained before operation fromGiant Industries, Inc.4. Run the pump dry approximately 10 seconds to drain thewater before exposure to freezing temperatures.3Volume ................................................................................................... Up to 18.5 GPM (70 l/m)Discharge Pressure ................................................................................ Up to 870 PSI (0.42 bar)Speed ..................................................................................................... Up to 570 RPMInlet Pressure ......................................................................................... -4.35* -150PSIPower Consumption ................................................................................ 12 HPPlunger Diameter .................................................................................... 36mmPlunger Stroke ........................................................................................ 42mmCrankshaft Diameter .............................................................................. 35mmKey Width .............................................................................................. 8mmCrankshaft Mounting .............................................................................. Either sideShaft Rotation ............................................................................. Top of pulley towards manifoldTemperature of Pumped Fluids ............................................................... Up to 104 oF (40 oC)Inlet Ports ............................................................................................... (2) 1-1/2" NPTDischarge Ports ...................................................................................... (2) 1" NPTWeight .................................................................................................... 120 lbs.Crankcase Oil Capacity .......................................................................... 116 fl.oz. (3,430 ml)Fluid End Material .................................................................................. Cast IronSpecificationsModel BP5236Consult the factory for special requirements that must be met if the pump is tooperate beyond one or more of the limits specified above.* Depends on viscosity of mediumPULLEY INFORMATIONPulley selection and pump speed are based on a 1725RPM motor and "B" section belts. When selectingdesired GPM, allow for a ±5% tolerance on pumpsoutput due to variations in pulleys, belts and motorsamong manufacturers.1. Select GPM required, then select appropriatemotor and pump pulley from the same line.2. The desired pressure is achieved by selecting thecorrect nozzle size that corresponds with the pumpGPM.HORSEPOWER INFORMATIONWe recommend that a 1.1 service factor be specifiedwhen s electing an electric motor as the power source.To compute specific pump horsepower requirements,use the following formula:HP = (GPM X PSI) / 1440*Intermittent duty only - Consult factoryBP5236 HORSEPOWERRPM GPM 250 PSI 500 PSI 750 PSI 1000 PSI100 3.2 0.6 1.1 1.7 2.3200 6.4 1.1 2.3 3.4 4.6300 10.0 1.8 3.6 5.4 7.1400 13.0 2.3 4.6 7.0 9.3570 18.5 3.3 6.6 9.9 13.24Exploded View - BP52365ITEM PART NO. DESCRIPTION QTY.1 06911 Crankcase 12 06912 Oil Filler Plug 14 06085 Crankcase Cover 15 07104 O-Ring 16 07186 Oil Sight Glass W/Gasket 18 06086 Oil Dipstick 19 01009 O-Ring 110 01010 Screw 411 08094 Spring Ring 512 07109 Plug 113 07182 Gasket 114 07111 Bearing Cover 215 07112 Crankshaft Seal 216 07113 O-Ring 217 07114 Hex Screw 820 07116 Taper Roller Bearing 220A 07117 Fitting Disc, 0.1mm 220B 13001 Fitting Disc, 0.15mm 321 07118 Shaft Protector 122 13242 Crankshaft 123 13243 Key 124 13340 Connecting Rod Assy. 325 06913 Crosshead PlungerBase Assy. 328 13232 Crosshead Pin 329A 07125 Centering Sleeve 329B 07130 Plunger Pipe (A-D) 329C 07131 Tensioning Screw 329D 07755 Copper Gasket 330 07779 Flinger (E) 3ITEM PART NO. DESCRIPTION QTY.31A 06118 Oil Seal 332 06116 Oil Seal Retainer 332A 06119 O-Ring 333 06117 Backup Seal 335 06914 Seal Sleeve 336 06915 Guide Ring 337 07139 Seal Case 338 07140 O-Ring 639 06916 Support Ring 640 06917 Spiral Ring 641 06918 Support Ring 342 07147 Tension Spring 343 06919 Valve Casing 144A 07150 O-Ring 944B 06266 Support Ring 345 06078 Spring 346A 06920 Valve Seat 646B 06921 Valve Plate 646C 07062 Valve Spring 646D 06922 Spacer Pipe Assembly 646E 06923 Gasket for Valve 648 06077 Plug 349 07154 Stud Bolt 849A 07158 Nut 849B 07159 Washer 850 07423 Plug 150A 07161 Gasket 152 13020 Disk for Crankshaft 153 06607 Hexagon Screw 1BP5236 PARTS LIST6BP5236 PUMP REPAIR KITSValve Assembly Kit#09570Item Part # Description Qty.44A 07150 O-Ring 944B 06266 Support Ring 346A 06920 Valve Seat 646B 06921 Valve Plate 646C 07062 Valve Spring 646D 06922 Spacer Pipe Assembly 646E 06923 Gasket for Valve 6Plunger Packing Kit# 09569Item Part # Description Qty.36 06915 Guide Ring 338 07140 O-Ring 639 06916 Support Ring 640 06917 Spiral Ring 6Position Item# Description Torque Amount10 01010 Screw, Cover 125 in.-lbs.17 07114 Hex Screw, Bearing Cover 125 in.-lbs.24A 13277 Hex Screw, Connecting Rod 250 in.-lbs.29C 07131 Plunger Bolt 26 ft.-lbs.48 06077 Plug, Valve 160 ft.-lbs.49A 07158 Nut, Stud Bolt 60 ft.-lbs.BP5236 TORQUE SPECIFICATIONSOil Packing Kit# 09571Item Part # Description Qty.31A 06118 Radial Shaft-Seal 332A 06119 O-Ring 333 06117 Compact Ring 3Preventative Maintenance Check-List & Recommended Spare Parts ListCheck Daily Weekly 50hrs Every Every Every500 hrs 1500 hrs 3000 hrsOil Level/Quality XOil Leaks XWater Leaks XBelts, Pulley XPlumbing XRecommended Spare PartsOil Change p/n 1154 X XPlunger Packing Kits (1 kit/pump) X(See page 7 for kit list)Valve Assembly Kit (1 kit/pump) X(See page 7 for kit list)Oil Seal Kit (1 kit/pump) X(See page 7 for kit list)7BP5236 - Repair Instructions1. Remove plugs (48) with a36mm wrench and check o-ring (44A) and support ring(44B) take out spring (45).2. Remove discharge and suc-tion valves (46), by pullingthem upwards out of thevalve casing with a valvepuller.3. The spacer pipe (46D) isscrewed together withvalve seat (46A).4. Unscrew the valve seat, remove the valve plate (46B) andspring (46C). The seal ring (46E) is snapped onto the valveplate. Check all sealing surfaces and replace worn parts.Tighten plugs (48) to 107 ft-lbs.5. Remove hexagon nuts(49A)6. Remove pump head by tap-ping from the back with arubber mallet.7. Remove seal unit (36, 39,40) out of seal sleeve.811. Clean plunger surface (25); using the tension screw, put thenew plunger pipe and a new copper gasket (29D) onto thecentering sleeve. Cover the threads of the tension screw lightlywith lock tight and tighten to 26 ft-lbs.IMPORTANT: Care must be taken that no lock tight getsbetween the plunger pipe (29B) and the centring sleeve (29A).The plunger pipe should not be strained by over tightening of thetension screw or through damage to front surface of plunger,otherwise it will probably break.12. Check o-rings (38) on sealcases (37). Clean mountingsurfaces of the seal casesas well as sealing surfacesin valve casing. Put sealcases (37) in the centringholes of the valve casing,then push valve casing care-fully onto stud bolts (49).BP5236 - Repair Instructions9. Examine spiral rings (40) and guide ring (36). Remove seal case(37) from valve casing and check O-rings (38). Replace wornparts; apply silicon grease on seals and o-rings before installing.10. Remove tension screw(29C) and remove theplunger pipe from centeringsleeve (29A)13. Tighten hexagon nuts (49)in a crossing pattern shownto the right to 59 ft-lbs.6 4 2 78 1 3 59Contact Giant Industries or your local distributor for maintenanceof the gear end of your pump. Phone: 419/531-4600Contact Giant Industries for service school information. Phone: (419) 531-4600BP5236 - Repair InstructionsTo Dismantle Gear End14. After removing valve casing and plunger pipes (29B) drain oil by removing drain plug (12). Removecrancase cover (4) and bearing cover (14). Remove connecting rod screws and push the front of theconnecting rods as far as possible into the crosshead guide.IMPORTANT: Connecting rods are marked for identification. Do not twist connecting rod halves.Connecting rods to be reinstalled in their exact original position on shaft journals.15. Turning the crankshaft slightly, hit it out carefully to the side with a rubber hammer.IMPORTANT: Do not bend the connecting rod shanks. Check shaft and connecting rod surfaces, shaftseals and taper roller bearings.To Reassemble16. Using a soft tool, press in the outer bearing ring till the outer edge line up with the outer edge of thebearing hole. Screw on bearing cover together with shaft seal and o-ring. Fit shaft through bearing holeon the opposite side. Press in outer bearing ring and tension it inwards with the bearing cover, keepingthe shaft in vertical position and turning slowly so that the taper rollers of the bearings touch the edgeof the outer bearing ring. Adjust axial bearing clearence to at least 0.1mm and maximum 0.15mm byplacing fitting discs (20A) under the bearing cover.IMPORTANT: After assembly has been completed, the shaft should turn easily with very littleclearence. Tighten connecting rod screws to 26 ft-lbs.Pump Mounting Selection GuideBushings01065 - 18 mm Tapered H BushingPulley & Sheaves01061 - 7.75” Cast Iron 1 gr. - AB Section01062 - 7.75” Cast Iron - 2 gr. - AB Section01066 - 18 mm - 8” Steel Pulley - 1 gr.Rails01034 - Steel Box Rails(L=9.25” x W=1.18” x H=1.62”)01075 - Plated Steel Channel Rails(L=9.00” x W=2.12” x H=2.50”)10PUMP SYSTEM MALFUNCTIONMALFUNCTION CAUSE REMEDYThe Pressure and/ Worn packing seals Replace packing sealsor the Delivery Broken valve spring Replace springDrops Belt slippage Tighten or Replace beltWorn or Damaged nozzle Replace nozzleFouled discharge valve Clean valve assemblyFouled inlet strainer Clean strainerWorn or Damaged hose Repair/Replace hoseWorn or Plugged relief valve on pump Clean, Reset, and Replace worn partsCavitation Check suction lines on inlet ofpump for restrictionsUnloader Check for proper operationWater in crankcase High humidity Reduce oil change intervalWorn seals Replace sealsNoisy Operation Worn bearings Replace bearings, Refill crankcaseoil with recommended lubricantCavitation Check inlet lines for restrictionsand/or proper sizingRough/Pulsating Worn packing Replace packingOperation with Inlet restriction Check system for stoppage, airPressure Drop leaks, correctly sized inletplumbing to pumpAccumulator pressure Recharge/Replace accumulatorUnloader Check for proper operationCavitation Check inlet lines for restrictionsand/or proper sizePressure Drop at Restricted discharge plumbing Re-size discharge plumbinggun flow rate of pumpExcessive Worn plungers Replace plungersLeakage Worn packing/seals Adjust or Replace packing sealsExcessive vacuum Reduce suction vacuumCracked plungers Replace plungersInlet pressure too high Reduce inlet pressureHigh Crankcase Wrong Grade of oil Giant oil is recommendedTemperature Improper amount of oil in crankcase Adjust oil level to proper amount11BP5236 Dimensions - Inches (mm)GIANT INDUSTRIES LIMITED WARRANTYGiant Industries, Inc. pumps and accessories are warranted by the manufacturer to be free from defects inworkmanship and material as follows:1. For portable pressure washers and self-service car wash applications, the discharge manifolds will neverfail, period. If they ever fail, we will replace them free of charge. Our other pump parts, used in portablepressure washers and in car wash applications, are warranted for five years from the dateof shipment forall 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 evaluationshows were defective at the time of shipment by the manufacturer. The following items are NOT covered or will voidthe 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 OperationsManuals 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 returnedfreight prepaid to Giant Industries which are deemed to be defective due to workmanship or failure of material. AReturned Goods Authorization (R.G.A.) number and completed warranty evaluation form is required prior to thereturn to Giant Industries of all products under warranty consideration. Call (419)-531-4600 or fax (419)-531-6836to obtain an R.G.A. number.Repair or replacement of defective products as provided is the sole and exclusive remedy provided hereunder andthe MANUFACTURER SHALL NOT BE LIABLE FOR FURTHER LOSS, DAMAGES, OR EXPENSES, INCLUDINGINCIDENTAL AND CONSEQUENTIAL DAMAGES DIRECTLY OR INDIRECTLY ARISING FROM THE SALE ORUSE OF THIS PRODUCT.THE LIMITED WARRANTY SET FORTH HEREIN IS IN LIEU OF ALL OTHER WARRANTIES OR REPRESENTA-TION, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION ANY WARRANTIES OR MERCHANTABILITYOR FITNESS FOR A PARTICULAR PURPOSE AND ALL SUCH WARRANTIES ARE HEREBY DISCLAIMED ANDEXCLUDED BY THE MANUFACTURER.GIANT INDUSTRIES, INC., 900 N. Westwood Avenue, P.O. Box 3187, Toledo, OH 43607PHONE: (419) 531-4600, FAX: (419) 531-6836, www.giantpumps.com Ó Copyright 2002 Giant Industries, Inc.08/02 BP5236.PM6