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It maybe necessary to use a slide hammer tool. 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 6) Remove the eight (8) manifold nuts and washers (49A,B) using a 19mm wrench and pull off valve casing (43). 7) If needed, tap valve casing with a rubber mallet to remove it. 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 assembly breaks free. 5) Replace tension plugs (48) and tighten them securely. 8) Using two flat screw drivers, pry seal sleeve (35) out of crankcase guides. 9 REPAIR INSTRUCTION - LP350, LP400, LP450 IBi V< 9) Remove seal case (37) from seal sleeve (35). 10) Check plunger surface (25 and 29B) for wear and pitting. If none is found, proceed to step twelve. 11) If plunger (29B) is worn, remove tension screw (29C) with a 17mm wrench. Clean tension screw with wire brush to remove any old locktite. Discard copper gasket (29D) and replace with new. Clean the front surface of plunger/ crosshead assembly (25). Install new plunger (29B) onto plunger/ crosshead assembly. Put some locktite on both surfaces of copper gasket and tension screw threads. Secure plunger in place with tension screw and gasket and tighten to 33 ft.-lbs. 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). 14) Replace nuts and washers (49a, B) and tighten to 59 ft.-lbs. in the pattern as shown to the right. 13) Place entire manifold assembly sleeve assembly over the studs (49) and push firmly until seated against the crankcase (1). 10 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 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. For portable pressure washers and 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 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 ofwhich 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 specificat...

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