Triplex Ceramic
Plunger Pump
Operating Instructions/
Repair and Service
Manual
Models
LP350, LP400, LP450
Contents:
Installation Instructions:
PumpSpecifications:
Exploded View:
page 2
pages 3-5
page 6
Parts List/Kits/Torque Specs: page 7
Trouble Shooting Chart:
Spare Parts List:
page 8
page 8
Repair Instructions:
Dimensions:
Warranty Information:
page 9-11
back page
back page
Updated 2/02
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Specifications
Model LP350
Volume ................................................................................................... Up to 22.6 GPM
Discharge Pressure ................................................................................. 2350 PSI
Inlet Pressure.......................................................................................... Up to 90 PSI
Maximum Crankshaft Speed ................................................................... Up to 1000 RPM
Plunger Diameter.................................................................................... 30mm
Stroke..................................................................................................... 42mm
Crankcase Oil Capacity .......................................................................... 100 fl.oz.
Temperature of Pumped Fluids ............................................................... 140 oF @1000 RPM
............................................................................................................... 160 oF Up to 500 RPM
Inlet Port ................................................................................................ 1-1/4" BSP+
Discharge Port ........................................................................................ 1" BSP++
Shaft Mounting ...................................................................................... Either side
Shaft Rotation ............................................................................ Top of pulley towards manifold
Weight.................................................................................................... 105 lbs.
Crankshaft Diameter ............................................................................... 35mm
+
++
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
amongmanufacturers.
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 require-
ments for the pump. Gas engine power outputs
must be approximately twice the pump power
requirements shown above.
We recommend that a 1.1 service factor be specified
when selecting an electric motor as the power source.
To compute specific pump horsepower requirements,
use the following formula:
HP = (GPM x PSI) / 1440
LP350 PULLEY SELECTION AND HORSEPOWER
REQUIREMENTS
PUMP MOTOR
PULLEY PULLEY
RPM GPM 500 PSI 1000 PSI 2000 PSI 2300 PSI
12.75"
12.75"
12.75"
12.75"
12.75"
12.75"
12.75"
3.95"
4.95"
5.75"
6.15"
6.55"
6.95"
500 11.3
640 14.5
750 16.9
805 18.2
865 19.5
940 21.2
3.9
5.0
5.9
6.3
6.8
7.4
7.8
7.8
15.7
20.1
23.5
25.3
27.1
29.5
31.4
18.0
23.1
27.1
29.0
31.2
33.9
36.1
10.0
11.8
12.6
13.6
14.7
15.7
7.50" 1000 22.6
3
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Specifications
Model LP400
Volume ................................................................................................... Up to 15.1 GPM
Discharge Pressure ................................................................................. 3600 PSI
Inlet Pressure.......................................................................................... Up to 90 PSI
Maximum Crankshaft Speed ................................................................... Up to 1000 RPM
Plunger Diameter.................................................................................... 24mm
Stroke..................................................................................................... 42mm
Crankcase Oil Capacity .......................................................................... 100 fl.oz.
Temperature of Pumped Fluids ............................................................... 140 oF @1000 RPM
............................................................................................................... 160 oF Up to 500 RPM
Inlet Port ................................................................................................ 1-1/4" BSP
Discharge Port ........................................................................................ 1" BSP
Shaft Mounting....................................................................................... Either side
Shaft Rotation ............................................................................ Top of pulley towards manifold
Weight.................................................................................................... 105 lbs.
Crankshaft Diameter ............................................................................... 35mm
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
amongmanufacturers.
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 require-
ments for the pump. Gas engine power outputs
must be approximately twice the pump power
requirements shown above.
We recommend that a 1.1 service factor be specified
when selecting an electric motor as the power source.
To compute specific pump horsepower requirements,
use the following formula:
HP = (GPM x PSI) / 1440
LP400 PULLEY SELECTION AND HORSEPOWER
REQUIREMENTS
PUMP MOTOR
PULLEY PULLEY
RPM GPM 2000 PSI 2500 PSI 3000 PSI 3600 PSI
12.75"
12.75"
12.75"
12.75"
12.75"
12.75"
12.75"
3.95"
4.95"
5.75"
6.15"
6.55"
6.95"
500 7.5
640 9.6
750 11.3 15.7
805 12.1 16.8
865 13.0 18.1
940 14.2 19.7
10.5
13.4
13.1
16.7
19.6
21.0
22.6
24.6
26.1
15.7
20.1
23.5
25.3
27.1
29.5
31.4
18.8
24.1
28.2
30.3
32.6
35.4
37.6
7.50" 1000 15.1 20.9
4
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Specifications
Model LP450
Volume ................................................................................................... Up to 19.7 GPM
Discharge Pressure ................................................................................. 2600 PSI
Inlet Pressure.......................................................................................... Up to 90 PSI
Maximum Crankshaft Speed ................................................................... Up to 1000 RPM
Plunger Diameter.................................................................................... 28mm
Stroke..................................................................................................... 42mm
Crankcase Oil Capacity .......................................................................... 100 fl.oz.
Temperature of Pumped Fluids ............................................................... 140 oF @1000 RPM
............................................................................................................... 160 oF Up to 500 RPM
Inlet Port ................................................................................................ 1-1/4" BSP
Discharge Port ........................................................................................ 1" BSP
Shaft Mounting....................................................................................... Either side
Shaft Rotation............................................................................. Top of pulley towards manifold
Weight.................................................................................................... 105 lbs.
Crankshaft Diameter ............................................................................... 35mm
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
amongmanufacturers.
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 require-
ments for the pump. Gas engine power outputs
must be approximately twice the pump power
requirements shown above.
We recommend that a 1.1 service factor be specified
when selecting an electric motor as the power source.
To compute specific pump horsepower requirements,
use the following formula:
HP = (GPM x PSI) / 1440
LP450 PULLEY SELECTION AND HORSEPOWER
REQUIREMENTS
PUMP MOTOR
PULLEY PULLEY
RPM GPM 1000 PSI 1500 PSI 2000 PSI 2600 PSI
12.75"
12.75"
12.75"
12.75"
12.75"
12.75"
12.75"
3.95"
4.95"
5.75"
6.15"
6.55"
6.95"
500 9.8
640 12.6
750 14.8 10.3
805 15.8 11.0
865 17.0 11.8
940 18.5 12.8
6.8
8.7
10.3
13.1
15.4
16.5
17.7
19.3
20.5
13.7
17.5
20.5
22.0
23.6
25.7
27.3
17.8
22.7
26.7
28.6
30.7
33.4
35.5
7.50" 1000 19.7 13.7
5
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LP350, LP400, LP450 - EXPLODED VIEW
6
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LP350, LP400 & LP450 PARTS LIST
ITEM #
35
37
37
38
38
38A
39
39
39
40
40
40
41
41
41
42
42
PART #
06650
13393
06651
07140
07700
12055
07271
13016
13013
13016
06083
13015
07273
13367
06652
07338
14084
13018
07150
06266
06078
07060
07064
07063
07062
07066
07156
07754
07158
07159
07423
07161
13020
06607
DESCRIPTION
Seal Sleeve(LP350,LP450)
Seal Case(LP400)
SealCase(LP350/LP450)
O-Ring(LP400)
O-Ring(LP350/LP450)
O-Ring(LP400Only)
Pressure Ring(LP350)
Pressure Ring(LP400)
Pressure Ring(LP450)
V-Sleeve(LP350)
V-Sleeve(LP400)
V-Sleeve(LP450)
Support Ring(LP350)
Support Ring(LP400)
Support Ring(LP450)
Pressure Spring(LP400)
Pressure Spring(LP350/LP450)
Valve Casing
O-Ring
Support Ring
CompressionSpring
Valve Assy.
Valve Seat
Valve Plate
Valve Spring
Spacer Pipe
Plug
QTY
3
3
3
3
6
3
3
3
3
6
6
6
3
3
3
3
3
1
9
3
3
6
6
6
6
6
3
8
8
8
1
1
1
1
ITEM #
1
2
4
5
6
8
9
10
11
12
13
14
15
16
17
20
PART #
07759
13000
06085
07104
07186
06086
01009
01010
01011
07109
07182
07111
07112
07113
07114
07116
07117
13001
07118
13242
13243
13340
13277
13278
13244
13232
07256
13046
13005
07261
13007
07258
07779
07133
13392
DESCRIPTION
Crankcase
QTY
1
1
1
1
1
1
1
4
5
1
1
2
2
2
8
2
1-3
1-3
1
1
1
3
6
6
3
3
3
3
3
3
3
3
3
Oil filler plug assy.
Crankcase Cover
O-ring, Crankcase cover
Oil Sightglass with Gasket
Oil Dipstick
O-Ring, Dipstick
Cylinder Screw
Spring Ring
Plug
Gasket
Bearing Cover
Radial Shaft Seal
O-Ring
Hexagon Screw
Taper Roller Bearing
Fitting Disc
Fitting Disc (May not be present)
ShaftProtector
Crankshaft
20A
20B
21
22
23
43
44A
44B
45
WoodruffKey
46
24
Connecting Rod Assy.
Inner Hexagon Screw
Spring Washer
Crosshead / Plunger Assy.
CrossheadPin
Centeringsleeve
Plunger Pipe(LP400)
Plunger Pipe(LP450)
Plunger Pipe(LP350)
Tensioning Screw
Copper Ring
46A
46B
46C
46D
48
24A
24B
25
28
29A
29B
29B
29B
29C
29D
30
49
Stud bolt
Hexagon Nut
Disc
Plug, 1/4" BSP
Copper Ring
Disc for Crankshaft
Hexagon Screw
49A
49B
50
50A
52
O-Ring
Oil Seal
Seal Sleeve(LP400)
53
31
35
3
3
LP350, LP400 & LP450 KITS
Pumps Manufactured After 2/97
Pumps Manufactured Prior to 2/97
Packing Kit, LP350
(after 2/97)
#09546
Valve Kit
Item Part # Description
#09196
Qty
Packing Kit, LP350
(prior to 2/97)
#09233
Item Part # Description Qty
44A 07150 O-Ring
6
3
1
1
1
Item Part # Description Qty
38
07700 O-Ring
6
44B 06266 Support Ring
46A 7064 Valve seat
46B 7063 Valve plate
46C 7062 Valve spring
38
7140 O-ring
3
3
6
3
40
13016 V-Sleeve
6
38A 13012 O-ring
40
41
13016 V-sleeve
7150 O-ring
Packing Kit LP400
(after to 2/97)
#09548
Item Part # Description Qty
Packing Kit, LP400
(prior to 2/97)
Item Part # Description Qty
#09309
38
38A 12055 O-ring
40 06083 V-sleeve
07140 O-ring
3
3
6
38
38A 13012 O-ring
40 13049 V-sleeve
07140 O-ring
3
3
3
3
Packing Kit LP450
(after to 2/97)
#09549
TORQUE SPECIFICATIONS
40A 13050 Support-ring
Item Part # Description Qty
Position Description
TorqueAmount
264 in.-lbs.
33 ft.-lbs.
24
Connecting Rod
Tensioning Screw
Hexagon Nut
38
40
07700 O-ring
13015 V-Sleeve
6
6
Packing Kit LP450
(prior to 2/97)
#09234
29C
49A
59 ft.-lbs.
Item Part # Description Qty
38
07140 O-ring
3
3
6
3
38A 12055 O-ring
40
41
13015 V-Sleeve
06652 O-ring
7
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PUMP SYSTEM MALFUNCTION
MALFUNCTION
CAUSE
REMEDY
The Pressure and/
or the Delivery
Drops
Worn packing seals
Broken valve spring
Belt slippage
Replace packing seals
Replace spring
Tighten or Replace belt
Replace nozzle
Worn or Damaged nozzle
Fouled discharge valve
Fouled inlet strainer
Worn or Damaged hose
Worn or Plugged relief valve on pump
Cavitation
Clean valve assembly
Clean strainer
Repair/Replace hose
Clean, Reset, and Replace worn parts
Check suction lines on inlet of
pump for restrictions
Unloader
Check for proper operation
Water in crankcase
Noisy Operation
High humidity
Worn seals
Reduce oil change interval
Replace seals
Worn bearings
oil with
Cavitation
Replace bearings, Refill crankcase
recommended lubricant
Check inlet lines for restrictions
and/or proper sizing
Rough/Pulsating
Operation with
Pressure Drop
Worn packing
Inlet restriction
Replace packing
Check system for stoppage, air
leaks, correctly sized inlet
plumbing to pump
Accumulator pressure
Unloader
Cavitation
Recharge/Replace accumulator
Check for proper operation
Check inlet lines for restrictions
and/or proper size
Pump Pressure as
gun
Rated, Pressure
Restricted discharge plumbing
Re-size discharge plumbing to Drop at
flow rate of pump
Excessive
Leakage
Worn plungers
Replace plungers
Worn packing/seals
Excessive vacuum
Cracked plungers
Inlet pressure too high
Adjust or Replace packing seals
Reduce suction vacuum
Replace plungers
Reduce inlet pressure
High Crankcase
Temperature
Wrong Grade of oil
Improper amount of oil in crankcase
Giant oil is recommended
Adjust oil level to proper amount
Preventative Maintenance Check-List & Recommended Spare Parts List
Check
Daily
Weekly
50hrs
Every
500 hrs
Every
1500 hrs
Every
3000 hrs
Oil Level/Quality
Oil Leaks
Water Leaks
Belts, Pulley
Plumbing
X
X
X
X
X
Recommended Spare Parts
Oil Change (1 Gallon) p/n 1154
Seal Spare Parts (1 kit/pump)
(See page 7 for kit list)
X
X
X
X
Oil Seal Kit (1 kit/pump)
(See page 7 for kit lit)
Valve Spare Parts (1 kit/pump)
(See page 7 for kit list)
X
8
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REPAIR INSTRUCTION - LP350, LP400, LP450
TO CHECK VALVES
2) Remove discharge and inlet
valve assemblies (46) by
pulling them upwards out of
the valve casing (43). It
maybe necessary to use a
slide hammer tool.
3) With the valve assembly (46)
pointed down, place a dowel
rod through the top of spacer
pipe (46D). Hold assembly
in hand and tap end of dowel
sharply with mallet until as-
sembly breaks free.
1) With a 30mm wrench
remove the three (3)
tension plugs (48) from top
of valve casing (43).
46D
46C
46B
46A
44A
5) Replace tension plugs (48)
and tighten them securely.
4) Inspect valve seats (46A) and valve plates (46B) for damage
and replace if needed. Check valve casing (43) surfaces for
damage. Replace o-rings (44A) and reinstall valve assemblies
(46) into valve casing. (Lubricate o-rings before installation.)
SEAL AND PLUNGER REPLACEMENT
7) If needed, tap valve casing
with a rubber mallet to re-
move it.
8) Using two flat screw drivers,
pry seal sleeve (35) out of
crankcase guides.
6) Remove the eight (8)
manifold nuts and washers
(49A,B) using a 19mm
wrench and pull off valve
casing (43).
9
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REPAIR INSTRUCTION - LP350, LP400, LP450
10) Check plunger surface (25
and 29B) for wear and pit-
ting. If none is found, pro-
ceed to step twelve.
11) If plunger (29B) is worn, re-
move tension screw (29C)
with a 17mm wrench. Clean
tension screw with wire
brush to remove any old
locktite. Discard copper gas-
ket (29D) and replace with
new. Clean the front surface
of plunger/ crosshead as-
sembly (25). Install new
plunger (29B) onto plunger/
crosshead assembly. Put
some locktite on both sur-
faces of copper gasket and
tension screw threads. Se-
cure plunger in place with
tension screw and gasket
and tighten to 33 ft.-lbs.
9) Remove seal case (37) from
seal sleeve (35).
35
39
40 (2) 41
42 38
38A 37
38
(LP400 only)
12) Remove v-sleeves (40) and support ring (41) for seal case (37)
and replace with new elastomers. Lubricate parts before
reinstalling into seal sleeve. Replace seal sleeve/seal case
assembly (35/37) into the valve casing (43).
13) Placeentiremanifold assem-
bly sleeve assembly over the
studs (49) and push firmly
untilseatedagainstthecrank-
case (1).
14) Replace nuts and washers
(49A, B) and tighten to 59 ft.-lbs.
in the pattern as shown to the
right.
6
8
7
5
4
1
2
3
10
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REPAIR INSTRUCTIONS - LP350, LP400, LP450
DISASSEMBLY OF CRANKCASE
1) Remove valve casing (43) and plunger pipe (29B), drain oil.
2) Screw off gear cover (4) and bearing cover (14).
3) Remove connecting rod screws (24) and push the front of connecting rod forward as far as possible. Remove
back halves of connecting rods, note which position from which they came from.
4) Turning the crankshaft slightly, carefully hit on side of crankshaft (22) with a rubber mallet until crankshaft is
loose.
CAUTION: Do not bend the connecting rod shafts. Check cranshaft and connecting rod surfaces, shaft
seals and taper roller bearings.
REASSEMBLY
5) Using a soft tool, press in the outer bearing ring until the outer edge lines up with the outer edge of the
bearing hole (1).
6) Remove the bearing cover (14) together with the shaft seal (15) and o-ring (16). Fit crankshaft through
bearing hole on the opposite side.
7) Press in outer bearing (20) inwards with the bearing cover (14). Make sure that the crankshaft is in a vertical
position and turn it slowly so that the taper rollers of the bearings touch the edge of outer bearing ring.
8) Adjust axial bearing clearance to at least .004” and maximum at .006” by placing fitting discs (20A and/or
20B) under the bearing cover (14).
CAUTION: After assembly has been completed, the crankshaft should turn easily and with very
little clearance.
9) Bolt connecting rod halves together making sure they are replaced in the same position from which they
came. Tighten connecting rod screws to 264 in.-lbs.
11
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LP350, LP400 & LP450 DIMENSIONS (inches)
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. Forportablepressurewashers andcarwashapplications, thedischargemanifolds 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 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.
Thiswarrantyislimitedtorepairorreplacementofpumpsandaccessoriesofwhichthe 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
workmanshiporfailureofmaterial. AReturnedGoodsAuthorization(R.G.A.)numberandcompleted
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.
Repair or replacement of defective products as provided is the sole and exclusive remedy provided
hereunderandtheMANUFACTURERSHALLNOTBELIABLEFORFURTHERLOSS,DAMAGES,
OR EXPENSES, INCLUDING INCIDENTAL AND CONSEQUENTIAL DAMAGES DIRECTLY OR
INDIRECTLY ARISING FROM THE SALE OR USE OF THIS PRODUCT.
THE LIMITED WARRANTYSETFORTH HEREIN IS IN LIEU OF ALL OTHER WARRANTIES OR
REPRESENTATION, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION ANY WAR-
RANTIESORMERCHANTABILITYORFITNESSFORAPARTICULARPURPOSEANDALLSUCH
WARRANTIES ARE HEREBYDISCLAIMEDANDEXCLUDEDBYTHE MANUFACTURER.
GIANT INDUSTRIES, INC. 900 N. Westwood Ave., P.O. Box 3187, Toledo, Ohio 43607
Ó Copyright 2002 Giant Industries, Inc.
2/02 LP350.PM6
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