Giant BP5236 User manual

Triplex Ceramic
Plunger Pump
Operating Instructions/
Repair and Service
Manual
Contents:
InstallationInstructions: page 2
PumpSpecifications: page 3
ExplodedView: page 4
PartsList: page 5
KitList/Torque
Specifications: page 6
RecommendedSpare
PartsList: page 6
RepairInstructions: pages 7-9
PumpMountingSelectionGuide: page 9
TroubleShooting: page10
Dimensions: page 11
WarrantyInformation: back page
Model
BP5236

2
NOTE: Contact Giant Industries for Service School Information. Phone: [phone]
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. If pumps are to be operated at temperatures in
excess of 1600F, it is important to insure a positive head
to the pump to prevent cavitation. See NPSH curve.
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.
IMPORTANT OPERATING CONDITIONS
Failure to comply with any of these conditions invalidates the warranty.
1. Prior to initial operation, add oil to the crankcase so that
oil level is between the two lines on the oil dipstick. DO
NOT OVERFILL.
Giant Oil Recommended
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.
4. Use of a dampener is necessary to minimize pulsation at
drive elements, plumbing, connections, and other system
areas. The use of a dampener with Giant Industries, Inc.
pumps is optional, although recommended by Giant
Industries, Inc. to further reduce system pulsation.
Dampeners can also reduce the severity of pressure spikes
that occur in systems using a shut-off gun. A dampener
must be positioned downstream from the unloader.
5. Crankshaft rotation on Giant Industries, Inc. pumps
should be made in the direction designated by the arrows on
the pump crankcase. 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.
6. 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.
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.

3
Volume ................................................................................................... Up to 18.5 GPM (70 l/m)
Discharge Pressure ................................................................................ Up to 870 PSI (0.42 bar)
Speed ..................................................................................................... Up to 570 RPM
Inlet Pressure ......................................................................................... -4.35* -150PSI
Power Consumption................................................................................ 12 HP
Plunger Diameter.................................................................................... 36mm
Plunger Stroke ........................................................................................ 42mm
Crankshaft Diameter .............................................................................. 35mm
Key Width .............................................................................................. 8mm
Crankshaft Mounting .............................................................................. Either side
Shaft Rotation.............................................................................Top of pulley towards manifold
Temperature of Pumped Fluids ............................................................... Up to 104 oF (40 oC)
Inlet Ports............................................................................................... (2) 1-1/2" NPT
Discharge Ports ...................................................................................... (2) 1" NPT
Weight .................................................................................................... 120 lbs.
Crankcase Oil Capacity .......................................................................... 116 fl.oz. (3,430 ml)
Fluid End Material .................................................................................. Cast Iron
Specifications
Model BP5236
Consult the factory for special requirements that must be met if the pump is to
operate beyond one or more of the limits specified above.
* Depends on viscosity of medium
PULLEY INFORMATION
Pulley selection and pump speed are based on a 1725
RPM motor and "B" section belts. When selecting
desired GPM, allow for a ±5% tolerance on pumps
output due to variations in pulleys, belts and motors
among manufacturers.
1. Select GPM required, then select appropriate
motor and pump pulley from the same line.
2. The desired pressure is achieved by selecting the
correct nozzle size that corresponds with the pump
GPM.
HORSEPOWERINFORMATION
We recommend that a 1.1 service factor be specified
when 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 factory!
BP5236 HORSEPOWER
RPM GPM 250 PSI 500 PSI 750 PSI 1000 PSI
100 3.2 0.6 1.1 1.7 2.3
200 6.4 1.1 2.3 3.4 4.6
300 10.0 1.8 3.6 5.4 7.1
400 13.0 2.3 4.6 7.0 9.3
570 18.5 3.3 6.6 9.9 13.2

4
Exploded View - BP5236

5
ITEM PARTNO. DESCRIPTION QTY.
106911 Crankcase 1
206912 OilFillerPlug 1
406085 CrankcaseCover 1
507104 O-Ring 1
607186 OilSightGlassW/Gasket 1
806086 OilDipstick 1
901009 O-Ring 1
10 01010 Screw 4
11 08094 SpringRing 5
12 07109 Plug 1
13 07182 Gasket 1
14 07111 BearingCover 2
15 07112 CrankshaftSeal 2
16 07113 O-Ring 2
17 07114 Hex Screw 8
20 07116 TaperRollerBearing 2
20A 07117 FittingDisc,0.1mm 2
20B 13001 FittingDisc,0.15mm 3
21 07118 ShaftProtector 1
22 13242 Crankshaft 1
23 13243 Key 1
24 13340 ConnectingRodAssy. 3
25 06913 CrossheadPlunger
BaseAssy. 3
28 13232 CrossheadPin 3
29A 07125 CenteringSleeve 3
29B 07130 PlungerPipe(A-D) 3
29C 07131 TensioningScrew 3
29D 07755 CopperGasket 3
30 07779 Flinger(E) 3
ITEM PARTNO. DESCRIPTION QTY.
31A 06118 OilSeal 3
32 06116 OilSealRetainer 3
32A 06119 O-Ring 3
33 06117 BackupSeal 3
35 06914 Seal Sleeve 3
36 06915 GuideRing 3
37 07139 Seal Case 3
38 07140 O-Ring 6
39 06916 SupportRing 6
40 06917 SpiralRing 6
41 06918 SupportRing 3
42 07147 TensionSpring 3
43 06919 ValveCasing 1
44A 07150 O-Ring 9
44B 06266 SupportRing 3
45 06078 Spring 3
46A 06920 ValveSeat 6
46B 06921 ValvePlate 6
46C 07062 ValveSpring 6
46D 06922 SpacerPipeAssembly 6
46E 06923 GasketforValve 6
48 06077 Plug 3
49 07154 StudBolt 8
49A 07158 Nut 8
49B 07159 Washer 8
50 07423 Plug 1
50A 07161 Gasket 1
52 13020 DiskforCrankshaft 1
53 06607 HexagonScrew 1
BP5236 PARTS LIST

6
BP5236 PUMP REPAIR KITS
Valve Assembly Kit
#09570
ItemPart # Description Qty.
44A 07150 O-Ring 9
44B 06266 SupportRing 3
46A 06920 ValveSeat 6
46B 06921 ValvePlate 6
46C 07062 ValveSpring 6
46D 06922 Spacer Pipe Assembly 6
46E06923 GasketforValve 6
Plunger Packing Kit
# 09569
ItemPart # Description Qty.
36 06915 GuideRing 3
38 07140 O-Ring 6
39 06916 Support Ring 6
40 06917 SpiralRing 6
Position Item# Description Torque Amount
10 01010 Screw, Cover 125in.-lbs.
17 07114 Hex Screw, Bearing Cover 125in.-lbs.
24A 13277 Hex Screw, Connecting Rod 250in.-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 SPECIFICATIONS
Oil Packing Kit
# 09571
ItemPart # Description Qty.
31A 06118 Radial Shaft-Seal 3
32A 06119 O-Ring 3
33 06117 CompactRing 3
PreventativeMaintenanceCheck-List& Recommended SparePartsList
Check Daily Weekly 50hrs Every Every Every
500 hrs 1500 hrs 3000 hrs
OilLevel/Quality X
OilLeaks X
Water Leaks X
Belts, Pulley X
Plumbing X
RecommendedSpareParts
OilChangep/n 1154 XX
Plunger Packing Kits(1kit/pump) X
(See page 7 for kit list)
ValveAssemblyKit (1 kit/pump) X
(See page 7 for kit list)
Oil Seal Kit (1 kit/pump) X
(See page 7 for kit list)

7
BP5236-RepairInstructions
1. Remove plugs (48) with a
36mm wrench and check o-
ring (44A) and support ring
(44B) take out spring (45).
2. Remove discharge and suc-
tion valves (46), by pulling
them upwards out of the
valve casing with a valve
puller.
3. The spacer pipe (46D) is
screwed together with
valve seat (46A).
4. Unscrew the valve seat, remove the valve plate (46B) and
spring (46C). The seal ring (46E) is snapped onto the valve
plate. 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 a
rubber mallet.
7. Remove seal unit (36, 39,
40) out of seal sleeve.

8
11. Clean plunger surface (25); using the tension screw, put the
new plunger pipe and a new copper gasket (29D) onto the
centering sleeve. Cover the threads of the tension screw lightly
with lock tight and tighten to 26 ft-lbs.
IMPORTANT: Care must be taken that no lock tight gets
between the plunger pipe (29B) and the centring sleeve (29A).
Theplungerpipeshouldnotbestrained by overtighteningofthe
tension screw or through damage to front surface of plunger,
otherwise it will probably break.
12. Check o-rings (38) on seal
cases (37). Clean mounting
surfaces of the seal cases
as well as sealing surfaces
in valve casing. Put seal
cases (37) in the centring
holes of the valve casing,
thenpushvalvecasingcare-
fully onto stud bolts (49).
BP5236-RepairInstructions
9. Examinespiralrings(40)and guidering(36).Removesealcase
(37) from valve casing and check O-rings (38). Replace worn
parts;applysilicongreaseonsealsando-ringsbeforeinstalling.
10. Remove tension screw
(29C) and remove the
plungerpipefromcentering
sleeve (29A)
13. Tighten hexagon nuts (49)
in a crossing pattern shown
to the right to 59 ft-lbs.
64 2 7
8135

9
Contact Giant Industries or your local distributor for maintenance
of the gear end of your pump. Phone: [phone]
Contact Giant Industries for service school information. Phone: [phone]
BP5236-RepairInstructions
To Dismantle Gear End
14. After removing valve casing and plunger pipes (29B) drain oil by removing drain plug (12). Remove
crancase cover (4) and bearing cover (14). Remove connecting rod screws and push the front of the
connecting 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, shaft
seals and taper roller bearings.
To Reassemble
16. Using a soft tool, press in the outer bearing ring till the outer edge line up with the outer edge of the
bearing hole. Screw on bearing cover together with shaft seal and o-ring. Fit shaft through bearing hole
on the opposite side. Press in outer bearing ring and tension it inwards with the bearing cover, keeping
the shaft in vertical position and turning slowly so that the taper rollers of the bearings touch the edge
of the outer bearing ring. Adjust axial bearing clearence to at least 0.1mm and maximum 0.15mm by
placing fitting discs (20A) under the bearing cover.
IMPORTANT: After assembly has been completed, the shaft should turn easily with very little
clearence. Tighten connecting rod screws to 26 ft-lbs.
Pump Mounting Selection Guide
Bushings
01065-18mmTaperedHBushing
Pulley & Sheaves
01061 - 7.75” Cast Iron 1 gr. - AB Section
01062 - 7.75” Cast Iron - 2 gr. - AB Section
01066 - 18 mm - 8” Steel Pulley - 1 gr.
Rails
01034 - Steel Box Rails
(L=9.25”xW=1.18”xH=1.62”)
01075-PlatedSteelChannelRails
(L=9.00”xW=2.12”xH=2.50”)

10
PUMPSYSTEMMALFUNCTION
MALFUNCTION CAUSE REMEDY
The Pressure and/ Worn packing seals Replace packing seals
or the Delivery Brokenvalvespring Replace spring
Drops Beltslippage Tighten or Replace belt
WornorDamagednozzle Replacenozzle
Fouled discharge valve Clean valve assembly
Fouledinletstrainer Cleanstrainer
Worn or Damaged hose Repair/Replace hose
Worn or Plugged relief valve on pump Clean,Reset,andReplacewornparts
Cavitation Check suction lines on inlet of
pumpforrestrictions
Unloader Check for proper operation
Water in crankcase Highhumidity Reduce oil change interval
Worn seals Replace seals
Noisy Operation Worn bearings Replacebearings,Refillcrankcase
oilwith recommendedlubricant
Cavitation Checkinletlinesforrestrictions
and/orpropersizing
Rough/Pulsating Worn packing Replacepacking
Operationwith Inletrestriction Check system for stoppage, air
Pressure Drop leaks,correctlysizedinlet
plumbingtopump
Accumulator pressure Recharge/Replaceaccumulator
Unloader Check for proper operation
Cavitation Checkinletlinesforrestrictions
and/or proper size
Pressure Drop at Restricteddischargeplumbing Re-sizedischargeplumbing
gun flow rate of pump
Excessive Worn plungers Replace plungers
Leakage Worn packing/seals Adjust or Replace packing seals
Excessivevacuum Reduce suction vacuum
Crackedplungers Replace plungers
Inlet pressure too high Reduce inlet pressure
High Crankcase Wrong Grade of oil Giant oil is recommended
Temperature Improper amount of oil in crankcase Adjust oil level to proper amount

11
BP5236 Dimensions - Inches (mm)

GIANT INDUSTRIES LIMITED WARRANTY
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 will never
fail, period. If they ever fail, we will replace them free of charge. Our other pump parts, used in portable
pressure washers and in car wash applications, are warranted for five years from the dateof 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 [phone]
to obtain an R.G.A. number.
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 REPRESENTA-
TION, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION ANY WARRANTIES 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 Avenue, P.O. Box 3187, Toledo, OH 43607
PHONE: [phone], FAX: [phone], www.giantpumps.com
Copyright 2002 Giant Industries, Inc. 08/02 BP5236.PM6