Giant BP100 User manual

Contents:

Installation Instructions: page 2

Pump Specications: page 3

Parts List: page 4

Exploded View / Kits: page 5

Recommended Spare Parts List: page 6

Pump Mounting Selection Guide: page 6

Torque Requirements: page 6

Repair Instructions: pages 7-10

Dimensions: page 11

Warranty Information: back page

Triplex Ceramic

Plunger Pump

Operating Instructions/

Repair and Service

Manual

Model

BP100

Bentonite Pump

Updated 04/22

Operation and Maintenance

Check oil level prior to starting and en-

sure trouble-free water supply . Oil: Use

only 23.7 ounces (0.7 litres) of Giant oil

(p/n 01154) ISO VG 220 (e.g. Aral Degol

BG220) or SAE 90 gear oil.

Initial change after 50 operating hours and

then every 1000 operating hours or after 1

year if used less.

Caution! When operating in damp places

or with high temperature uctuations.

Should condensate (frothy oil) occur in the

gear box, oil must be changed immediately.

Maximum input pressure 145 PSI (10

bar).

Maximum suction head -4.35 PSI (-0.3

bar) (dependent on the viscosity of the

medium). Maximum input pressure 145

PSI (10 bar), maximum suction head -4.35

PSI (-0.3 bar). Make sure that suction

pulsation is su󰀩ciently dampened - water

column resonance must be avoided.

Safety Rules

Pump operation without safety valve as

well as any excess in temperature or speed

limits automatically voids the warranty . The

safety valve must be regulated in accor-

dance with the guidelines for liquid spraying

units so that the admissible operating pres-

sure can not be exceeded by more than

10%.

When the pump is in operation, the open

shaft end must be oovered up by a shaft

protector (17). The driven shaft side and

coupling (or belt guard) should have a

metal guard over all moving parts.

Before any maintenance to the pump takes

place, the pressure in discharge line and in

pump must be at zero. Close suction line.

Disconnect fuses to ensure that the driving

motor is not accidentally switched on.

Before starting the pump, make sure that

all parts on the pressure side of the unit are

vented and relled (with pressure at zero).

In order to prevent air, or an air/water-mix-

ture being absorbed and to prevent cavita-

tion occurring, the pump-NPSHR, positive

suction head and medium temperature

must be kept under control.

Cavitation and/or compression of gases

lead to uncontrollable pressure-kicks

which can ruin pump and unit parts and

also be dangerous to the operator or

anyone standing nearby.

The BP100 pump is suitable for pumping

clean water as well as for water containing

bentonite in a concentration of maximum 55

lbs. (25 kg) of bentonite diluted in 264 gal-

lons (1 cubic meter) of water.

INSTALLATION INSTRUCTIONS

Specications

Model BP100

Consult the factory for special requirements that must be met if the

pump is to operate beyond one or more of the limits specied above.

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.

HORSEPOWER INFORMATION

Horsepower ratings shown are the power re-

quirements for the pump. Gas engine power

outputs must be approximately twice the pump

power requirements shown above.

We recommend that a 1.15 service factor be

specied when selecting an electric motor as the

power source. To compute specic pump horse-

power requirements, use the following formula:

(GPM X PSI) / 1450 = HP

U.S. (Metric)

Volume..................................................... 5.9 GPM................. (22.5 LPM)

Discharge Pressure ................................. 1885 PSI ................ (130 bar)

Maximum Crankshaft Speed ................................................... 750 RPM

Power Required....................................... 8.0 HP.................... (6.0 kW)

Plunger Diameter..................................... 1.02”....................... (26mm)

Stroke ...................................................... 0.79”....................... (20mm)

Crankcase Oil Capacity ........................... 24 .oz. .................. (0.7 L)

Temperature of Pumped Fluids................ 194 oF.................... (90o C)

Inlet Ports................................................................................. (2) 3/4” NPT

Discharge Ports ....................................................................... (2) 1/2” NPT

Crankshaft Mounting................................................................ Either Side

Shaft Rotation.......................................... Top of Pulley Towards Fluid End

Weight...................................................... 41.9 lbs. ................ (19 kg)

SPECIAL NOTE:

The theoretical gallons per revolution (gal/rev) is 0.0078667

To nd specic outputs at various RPM, use the formula:

GPM = 0.00787 x RPM

BP100 Horsepower Requirements

RPM GPM 500 PSI 1000 PSI 1500 PSI 1885 PSI

250 2.0 0.7 1.4 2.0 2.6

350 2.8 0.9 1.9 2.8 3.6

450 3.5 1.2 2.4 3.7 4.6

550 4.3 1.5 3.0 4.5 5.6

650 5.1 1.8 3.5 5.3 6.6

750 5.9 2.0 4.1 6.1 7.7

ITEM PART DESCRIPTIONS QTY

1 07294 Crankcase 1

2 06968 Oil Filler Cap with Gasket 1

3 07297 Cover, Crankcase 3

4 07298 O-Ring, Crankcase Cover 1

5 07299 Oil Dipstick 1

6 01009 O-Ring, Dip Stick 1

7 07186 Oil Sight Glass Assembly 1

9 01010 Screw, Crankcase Cover 4

10 01011-0400 Spring Washer, Cover Screw 4

11 07109 Oil Drain Plug 2

11A 06015 O-Ring 2

12 07302 Bearing Cover 2

13 07303 O-Ring, Bearing Cover 2

14 07459 Seal, Crankshaft 2

15 08388 Roller Bearing 2

15A 06962 Shim, 1.5mm 1-2

16 07114 Screw & Washer, Bearing Cover 6

17 05312 Shaft Protector 1

18 07309 Crankshaft 1

19 13331 Fitting Key 1

20 07310 Connecting Rod Assy. 3

20A 07311 Inner Hexagon Screw 3

20B 07122 Spring Washer 3

22 07315 Crosshead with Plunger Base 3

23 07314 Crosshead Pin 3

24 07360 Bolt Assembly

(Items 24B, 24C, 24D, 24E) 3

24A 07346 Ceramic Plunger 3

ITEM PART DESCRIPTIONS QTY

24B 08399 Tension Screw 3

24C 07023 O-Ring, Bolt Assy. (Viton) 3

24D 07203 Support Ring 3

24E 07258 Copper Seal Washer 3

25 05289 Flinger 3

26 07318 Radial Shaft Seal 3

28 07319 Shim, Stud 2

29 07320 Manifold 1

29A 11502 Inner Hexagon Stud Bolt 2

30 07335 Pressure Ring 3

31 11503 V-Sleeve 6

32 07349 Support Ring 3

33 07338 Pressure Spring 3

34 07325 Spring Retainer, Discharge 3

34A 07326-0100 Spring Retainer, Inlet 3

35 07312-0100 Valve Spring 6

36 07327 Valve Plate 6

37 06014 Valve Seat 6

38 06015 O-Ring, Valve Seat 6

39 07328 Valve Retainer, Inlet 3

39A 07329 Spacer 3

40 12057 O-Ring, Inlet Valve Retainer 3

41 07331 Plug, Inlet 3

42 07332 O-Ring, Inlet Plug 3

43 07213 Plug, Discharge 3

44 07214 O-Ring, Discharge Plug 3

45 07333 Stud Bolt 4

46 07158 Hex Nut, Stud Bolt 4

47 07159 Spring Washer, Stud Bolt 4

BP100 PARTS LIST

BP100 EXPLODED VIEW

Plunger Packing Repair - #09649

Item Part # Description Qty.

31 11503 V-Sleeve 6

40 12057 O-Ring, Inlet Valve Retainer 3

42 07332 O-Ring, Inlet Plug 3

Oil Seal Repair Kit - #09797

Item Part # Description Qty.

26 07318 Radial Shaft Seal 3

Valve Kit #09069

Item Part # Description Qty.

34 07325 Discharge Spring Retainer 3

34A 07326-0100 Inlet Spring Retainer 3

35 07312-0100 Valve Spring 6

36 07327 Valve Plate 6

37 06014 Valve Seat 6

38 06015 O-Ring, Valve Seat 6

40 12057 O-Ring, Inlet Valve Retainer 3

42 07332 O-Ring, Inlet Plug 3

44 07214 O-Ring, Discharge Plug 3

BP100 REPAIR KITS

May not be

present

Preventative Maintenance Check-List & Recommended Spare Parts List

Check Daily Weekly 50hrs Every Every Every

500hrs 1500hrs 3000hrs

500 hrs 1500 hrs 3000 hrs

Oil Level/Quality X

Oil Leaks X

Water Leaks X

Belts, Pulley X

Plumbing X

Recommended Spare Parts

Oil Change p/n 1154 X X

Plunger Packing Kits (1 kit/pump) X

(See page 5 for kit list)

Valve Assembly Kit (1 kit/pump) X

(See page 5 for kit list)

Oil Seal Kit (1 kit/pump) X

(See page 5 for kit list)

Pump Mounting Selection Guide

Bushings

07175 - 28 mm Tapered H Bushing

Pulley & Sheaves

01055 - 9.75” Cast Iron 2 gr. - AB Section

01062 - 7.75” Cast Iron - 2 gr. - AB Section

Rails

07358 - Plated Steel Channel Rails

(L=9.18” x W=1.88” x H=3.00”)

BP100 TORQUE SPECIFICATIONS

Position Part # Description Lubrication Info Torque Amount

7 07186 Oil Sight Glass Assembly Loctite 5910 106 in.-lbs. (12 Nm)

901010 Screw, Crankcase Cover 221 in.-lbs. (25 Nm)

11 07109 Oil Drain Plug 132 in.-lbs. (15 Nm)

16 07114 Screw Bearing Cover

20A 07311 Inner Hexagon Screw 22 ft.-lbs. (30 Nm)

24B 08399 Tension Screw Loctite 243 247 in.-lbs. (28 Nm)

26 07318 Radial Shaft Seal Loctite 403

41 07331 Plug, Inlet 51 ft.-lbs. (70 Nm)

43 07213 Plug, Discharge Loctite 243 51 ft.-lbs. (70 Nm)

45 07333 Stud Bolt Loctite 270

46 07158 Nut, Stud Bolt 200 in.-lbs. (22.5 Nm)

NOTE: Contact Giant Industries for Service School Information. Phone: (419)-531-4600

REPAIR INSTRUCTIONS - BP100 PUMP

1. With a 22mm socket, remove

the three discharge (43)

and three inlet (41) manifold

plugs.

2. Check o-ring (44) for wear and replace as necessary. Remove the

discharge spring retainer (34), valve spring (35), and valve plate

(36).

3. Use a small slide hammer

to remove valve seats (37)

from manifold (29). Inspect

valve plate (36) and valve

seats (37) for wear. If exces-

sive pitting is seen, replace

the worn parts. Check valve

seat o-ring (38) for wear and

replace as necessary.

4. Drain the oil from the pump.

Turn the pump over to remove

the four manifold stud nuts

(46) with a 19mm wrench.

5. Tap the back of the valve

41A 44 34 35 36

6. Remove the inlet valve re-

tainer assembly (34A-39)

7. Remove the o-ring, (40), valve plate (36), valve spring (35), spring

retainer (34A). Check valve retainer o-ring (40) for wear.

7A. Reassemble valve assemblies and install into manifold (29). Tighten

plugs to 52 ft.-lbs. (70 Nm).

casing (29) with a rubber mal-

let.

40 36 35 34A

NOTE: Contact Giant Industries for Service School Information. Phone: (419)-531-4600

REPAIR INSTRUCTIONS - BP100 PUMP

8. With a valve puller remove

the valve seat (37) and o-

ring (38).If excessive pitting

is seen, replace the worn

parts. Check valve seat o-ring

(38) for wear and replace as

necessary.

9. Remove the spacer (39A), pressure spring (33), support ring (32),

v-sleeves (31), and pressure ring (30), from the manifold (29) and

check for wear.

10.Inspect ceramic plunger

(24A) tips for wear. If nec-

essary, replacement of the

ceramic plungers may be

accomplished by removing

the plunger bolt assemblies

(24) with a 13mm wrench.

Ceramic plungers should now

slide o󰀨 the stainless steel

plunger base (22). Excessive

resistance to plunger removal

may be overcome by heating

the stainless steel plunger

base. This will melt any

excess loc-tite beneath the

ceramic plunger allowing easy

removal.

24E

11.Replace copper ring (24E)

onto plunger bolt (24B).

Slide plunger bolt assembly

(24) into ceramic plunger

(24A). Apply a light lm

of loc-tite to plunger bolt

threads and place plunger

assembly onto stainless

steel plunger base (22) and

tighten to 310 in.-lbs. (35

Nm).

12.To replace plunger oil seals

(26), proceed to “Gear End

Disassembly” section below.

Otherwise, continue as de-

scribed below.

13.Before replacing pump manifold (29), rst rotate crankshaft

(18) until two outside plungers (24A) extend evenly forward.

Lubricate ceramic plungers with a light lm of oil. Carefully

and evenly slide manifold over plungers and press manifold

rmly against crankcase (1). Replace manifold stud bolts

(45), washers (47) and nut (46) and tighten to 59 ft.-lbs. (80

Nm).

30 31 31 32 33 39A

Gear End Disassembly

14. Remove the crankcase cover screws (9). Inspect the crankcase cover o-ring (4) for wear. Replace if neces-

sary.

15. Inspect the dipstick (5) vent hole for signs of clogging. Clean if necessary.

16. To remove the crankshaft (18), rst remove the bearing cover plates (12). Remove the key (19).

17. With a 5 mm allen wrench remove the connecting rod screws (20A) and rear portion of connecting rod as-

semblies (20). Push the connecting rod (20) and plunger rod (22) down as far as possible into the crankcase

housing.

18. Hold the pump rear assembly with a wooden xture, or other suitable device, in order to secure it while re-

moving the crankshaft (18). Using a plastic mallet, tap the crankshaft from one side while turning it from the

other side. The turning insures that during this sequence the crankshaft does not become wedged against

the front portion of the connecting rods (20). The far side bearing (15) will remain in the crankcase (1). When

free, the crankshaft can be removed by hand. The opposite side crankshaft seal (14) will be removed by this

procedure. It is important that you turn the crankshaft (18) constantly while tapping from the opposite

end to avoid any binding. The crankshaft bearing (15) remains on the crankshaft as it is removed. If

necessary, use a bearing puller to remove the crankshaft bearing (15).

19. Remove the front portion of the connecting rods (20) and plunger base assembly (22) from the rear of the

pump by pulling straight out of the crankcase crosshead guides. Notice that the connecting rod (20) halves

are numbered or colored. Connecting rods must be positioned with their numbers or colors on the

upper left-hand side, in the same numerical sequence as when they were removed.

20. Using a dowel and a rubber mallet, tap the oil seals (26) out from the rear of crankcase (1). The area onto

which the oil seal rests should be clean and dry. Put a small drop of loc-tite on the oil seals and place into

crankcase with lips facing the rear of the pump.

21. To remove the crosshead pin (23) from the crosshead (22), the assembly should be positioned on a wooden

xture to avoid damage to crosshead. Drive out the pin on opposite side of mark located on the crosshead.

On those pumps without mark on crosshead, drive out pin by tapping on tapered side of pin.

22. To remove the bearing (15) remaining in the crankcase (1), insert small end of Giant bearing tool and tap with

a rubber mallet until bearing and seal (14) are completely removed. The bearing can only be removed from

the inside by inserting the Giant Bearing Tool through the opposite side of the crankcase. The cross-

head guide in the crankcase should be inspected for possible damage.

REPAIR INSTRUCTIONS - BP100 PUMP

23. To reassemble, place the far bearing (15) in the crankcase (1) bearing housing and with the Giant Bearing

tool as a driver, tap into the crankcase using a rubber mallet.

24. Insert the far side crankshaft oil seal (14) with the Giant Bearing Tool making sure it is rmly seated and well

oiled. Always make sure that the crankshaft seal lip does not show signs of wear and that the garter spring

is rmly in place on the seal before reinserting into the pump. Replace the bearing cover (12) and o-ring (13)

and tighten securely.

25. Replace the front portion of the connecting rod (20) and plunger rod/ crosshead assembly (22) by press-tting

the crosshead pin (23). Make sure to insert the beveled edge of the crosshead pin into crosshead. If the

crosshead has a mark, install pin from marked side. The crosshead pin (23) should not extend beyond

either side of the crosshead (22) in order to prevent damage to the crosshead bore of the crankcase

(1).

26. Place each crosshead/ plunger assembly into the pump making sure that all of the parts are well oiled before

insertion into the crankcase (1). Notice that the connecting rod (20) halves are numbered or colored.

Connecting rods must be positioned with their numbers or colors on the upper left-hand side, in the

same numerical sequence as when they were removed.

27. Replace near side bearing (15) on crankshaft by using the Giant Bearing Tool and mallet to tap into place.

Take the crankshaft (18) end with the bearing (15) and insert the other end through the bearing housing and

tap with a rubber mallet until the bearing is seated.

28. When reassembling the connecting rods (20), note that the connecting rod halves are numbered or colored

and that the numbers or colors must be matched and aligned. Torque the connecting rod bolts to 310 in.-lbs.

29. Insert the near side crankshaft oil seal (14) with the Giant Bearing Tool making sure it is rmly seated and well

oiled. Replace the bearing cover (12) and o-ring (13) and tighten securely.

 Seeinstructionsaboveforre-installinguidendontothegearend.

30. Fill the BP100 crankcase (1) with 23.7 oz. (0.7 liters) of Giant Industries’ oil and check the oil level with the

dipstick (5). Proper level is center of two lines. Reinstall the pump into your system.

REASSEMBLY INSTRUCTIONS - BP100 PUMP

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