Giant LP650 User manual

Contents:
Installation Instructions: page 2
Pump Specications: page 3
Exploded View: page 4
Parts, Kits, Torque: page 5
Repair Instructions: page 6
Dimensions: page 7
Warranty Information: back page
Triplex Ceramic
Plunger Pump
Operating Instructions/
Repair and Service
Manual
Model
LP650
Updated 09/21

2
INSTALLATION INSTRUCTIONS
When the pump is in operation, the open shaft
end must be covered up by a shaft protector
(21). For direct drive operations, the driven
shaft side and coupling must have a guard
over the connected area.
Pressure in discharge line and in pump must
be at zero before any maintenance to the
pump takes place. Close the uid supply to
the inlet port(s). Disconnect fuses to ensure
that the driving motor does not accidentally
get switched on. Make sure that all parts on
the pressure side of the unit are vented and
relled, with pressure at zero, before starting
the pump.
In order to prevent air, or air/water mixture
being absorbed and to prevent cavitation
occurring, the pump-npshr, positive suction
head and water temperature must be kept
under control.
Required NPSH refers to water: Specic
weight 0.0624 lb/ft3 (1kg/dm3), viscosity 1°E at
maximum permissible revolutions.
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.
Giant pumps are suitable for pumping clean
water and other non-aggressive or abrasive
media with a specic weight similar to water.
Before pumping other liquids - especially
inammable, explosive and toxic media
- the pump manufacturer must under all
circumstances be consulted with regard
to the resistance of the pump material.
It is the responsibility of the equipment
manufacturer and/or operator to ensure that
all pertinent safety regulations are adhered
to.
Operation and Maintenance
Check oil level prior to starting and ensure
trouble free water supply.
IMPORTANT! If there is a danger of frost,
the water in the pump and in the pump ttings
(particularly the unloader valve) must be
emptied. The second discharge port can
also be used and the pump run “dry” for 1-2
minutes for this purpose.
Oil: Use only 101 uid ounces (3.0 L) of SAE
90 Industrial gear lube oil. (Giant’s p/n 01154)
Initial change after 50 operating hours and
then every 1000 operating hours, or after one
year if used less.
Caution! When operating in damp places
or with high temperature uctuations,
condensate (frothy oil) might occur in the
gear box. In this situation, change the oil
immediately. Keep NPSH under control.
Maximum input pressure is 145 PSI (10
bar), the maximun suction head is -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 accordance with
the guidelines for liquid spraying units so that
the admissible operating pressure can not be
exceeded by more than 10%.
NOTE: Contact Giant Industries for Service School Information. Phone: [phone]

HORSEPOWER RATINGS:
The rating shown are the power requirements
for the pump. Gas engine power outputs
must be approximately twice the pump
power requirements shown above.
We recommend a 1.15 service factor be speci-
ed when selecting an electric motor as the
power source. To compute specic pump
horsepower requirements, use the Following
formula:
HP = (GPM X PSI) / 1450
3
SPECIFICATIONS MODEL LP650
U.S. Metric
Volume............................................................10.6 GPM ..................................................... 40.0 L/min
Maximum Discharge Pressure .......................6000 PSI........................................................... 400 Bar
Maximum Inlet Pressure.................................-4.35 to 87 PSI........................................... -0.3 to 6 Bar
Power Consumption .......................................42.2 BHP ..........................................................31.5 kW
RPM......................................................................................................................................1080 RPM
Plunger Diameter............................................0.79” ...................................................................20 mm
Stroke .............................................................1.65” ...................................................................42 mm
Crankcase Oil Capacity..................................101 . oz............................................................ 3 Liters
Temperature of Pumped Fluids ......................Up to 104 oF.......................................................... 40 oC
Inlet Port ............................................................................................................................2 x 3/4” BSP
Discharge Ports.................................................................................................................2 x 1/2” BSP
Shaft Rotation........................................................................................ Top of Pulley Toward Manifold
NPSHR...........................................................26.2 ft. of Head................................. 8 Meters of Water
Manifold Material ............................................................................................................. Forged Brass
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.
TORQUE SPECIFICATIONS
Pos. Item # Description Lubrication Info Torque Amount
1 07759 Crankcase Molycote Cu-Paste
605943 Oil Sight Glass Loctite 572 29 ft.-lbs (40 Nm)
10 01010 Cylinder Screw 221 in.-lbs (25 Nm)
12 07109 Plug 29 ft.-lbs (40 Nm)
17 07114 Hexagon Screw 221 in.-lbs. (25 Nm)
24 13340 Connecting Rod Assembly 22 ft.-lbs. (30 Nm)
29 06366 Plunger Loctite 243 26 ft.-lbs. (35 Nm)
31 07133 Radial Shaft Seal Loctite 403
46 13429 Stud Bolt Loctite 270
47 13430 Hexagon Nut 59 ft.-lbs. (80 Nm)
50 04122 Plug 107 ft.-lbs. (145 Nm)
LP650 HORSEPOWER CHART
RPM GPM 3000 PSI 4000 PSI 5000 PSI 6000 PSI
540 5.3 11.0 14.6 18.3 21.9
600 5.9 12.2 16.3 20.4 24.4
700 6.9 14.3 19.0 23.8 28.6
800 7.9 16.3 21.8 27.2 32.7
900 8.8 18.2 24.3 30.4 36.4
1080 10.6 21.9 29.2 36.6 43.9

4
LP650 EXPLODED VIEW

5
Item Part # Description Qty.
1 07759 Crankcase 1
2 13000 Oil Filler Plug Assembly 1
3 05940 Cover Plate 1
3A 07223-0100 Spring Ring 2
3B 05051 Hexagon Screw 2
4 06085 Crankcase Cover 1
5 07104 O-Ring 1
6 05943 Oil Sight Glass Assembly 1
8 06086 Oil Dipstick Assembly 1
9 01009 O-Ring 1
10 01010 Cylinder Screw 4
11 01011-0400 Spring Ring 5
12 07109 Plug, 1/2” BSP 1
13 06015 O-Ring 1
14 07111 Bearing Cover 2
15 07112 Radial Shaft Seal 2
16 07113 O-Ring 2
17 07114 Hexagon Screw 8
20 07116 Taper Roller Bearing 2
20A 07117 Fitting Disc 1-3
20B 13001 Fitting Disc 1-3
21 05376 Shaft Protector 1
21A 05377 Shaft Guard Mount 1
22 13242 Crankshaft 1
23 13243 Fitting Key 1
24 13340 Connecting Rod Assembly 3
24A 13277 Hexagon Screw 6
24B 07122 Spring Washer 6
25 13341 Crosshead/Plunger Assembly 3
28 13232 Crosshead Pin 3
29A 07125 Centering Sleeve 3
29B 07126 Plunger Pipe 3
29C 13031 Tensioning Screw 3
29D 07755 Copper Ring 3
30 07779 Oil Scraper 3
31 07133 Radial Shaft Seal 3
Item Part # Description Qty.
32 06584 Clip Ring 3
33 03281 Support Disc 3
33A 04615 Grooved Ring 3
33B 06240 Support Ring 3
35 03282 Seal Sleeve 3
35A 22764 Lock Pin 3
36 07268 Pressure Ring 3
37 07322 Sleeve 3
37A 05963 Sleeve 3
38 07270 Sleeve Support Ring 3
38A 13423 Spring 3
39 13424 Leakage Seal 3
40 05523 O-Ring 3
41 04118 O-Ring 3
42 04146 Seal Case 3
43 13426 Valve Retainer 3
44 04394 Valve Assembly (44A-44E) 6
44A 04395 Valve Retainer 6
44B 04396 Valve Spring 6
44C 04147 Valve Plate 6
44D 04121 Valve Seat 6
44E 04123 O-Ring 6
45 04560 Valve Casing 1
46 13429 Stud Bolt 8
47 13430 Hexagon Nut 8
48 07161 Copper Washer 3
49 07423 Plug, 1/4” BSP 3
50 04122 Valve Plug 3
51 05972 O-Ring 3
52 13020 Disc for Crankshaft 1
53 04561 Hexagon Screw 1
55 13434 Plug, 1/2” BSP 1
55A 06272 Copper Washer 1
56 07703 Plug, 3/4” BSP 1
56A 07704 Copper Washer 1
LP650 PARTS LIST
Plunger Packing Kit
#09837
Item Part # Description Qty.
33A 04615 Grooved Ring 3
33B 06240 Support Ring 3
36 07268 Pressure Ring 3
37 07322 Sleeve 3
38 07270 Sleeve Support Ring 3
39 13424 Leakage Seal 3
LP650 REPAIR KITS
Oil Seal Kit
#09577
Item Part # Description Qty.
31 07133 Radial Shaft Seal 3
Valve Assembly Kit
#09738
Item Part # Description Qty.
44 04394 Valve Assembly 6
51 05972 O-Ring 3

REPAIR INSTRUCTIONS - Model LP650
VALVE REPLACEMENT
1) Discharge Valves: Screw out tension plugs (50). take the spring tension cap (44A) out of the exposed discharge
valve with at nose pliers. Remove the valve seat (44D), if necessary with an M12 screw (screwing it into the M12
thread).
2) If the valve is extracted as a complete unit, position a screwdriver through the recess in the spring tension cap and
press down on the valve plate to gently lever the valve apart.
3) Check parts and replace if worn. Tighten plugs (50) at 107 ft-lbs. (145 Nm).
4) Suction Valves: Unscrew 8 nuts (47), remove valve casing (45) from seal sleeves (35). Using two screwdrivers, pry
out seal case (42) from valve casing. Remove spring tension cap (44A) with at nose pliers. Remove the valve seat
(44D), if necessary with an M12 screw (screwing it into the M12 thread). Check parts, and replace if worn.
NOTE: The leakage seal (39) with its 3mm bores must be positioned on to the notched pins (35A) situated on the seal
sleeve. Make sure the cutouts in the leakage seal are placed exactly over the bores of the seal sleeve (35) and that
the drip return bores in the valve casing are also free, to ensure trouble-free drip return.
6) Secure valve casing by tightening nuts (47) evenly to 59 ft.-lbs. (80 Nm).
SEAL AND PLUNGER REPLACEMENT
7) Unscrew the 8 x nuts (47), remove valve casing (45) by pulling it out to the front. Remove seal sleeves (35) from the
crankcase (1) guides. Remove seal case (42), tension spring (38A) and seal parts (36-38) from seal sleeve. Check
plunger surface (29B) and seals (37/37A) and remove pressure ring (36). Replace worn parts.
8) After removing clipring (32) and support ring (33), check weep seal and support ring (33A/33B); replace if necessary.
9) If the surface of the plunger is worn, remove tension screw (29C) and pull out the plunger (29B). Carefully clean front
surface of crosshead with plunger base (25).
10) Working from the pump drive side, carefully place the new plunger pipe (29B) through lubricated seals in the seal
sleeve (35). Using a properly sized tool, hold the seal sleeve in place.
11) Then insert seal sleeve (35) with plunger pipe (29B) into crankcase (1) guide. Turn crankshaft (22) until plunger with
crosshead (25) pushes against plunger (29B). Use new copper gasket (29D) and lightly coat threads of tension screw
(29C); attach to plunger base (25) and tighten to 26 ft.-lbs. (35 Nm).
IMPORTANT! Glue must never come between the plunger pipe (29B) and the centring sleeve (29A). Deformation of the
plunger pipe due to eccentric tightening of the tension screw or dirt or damage on the front surface can cause the
plunger pipe to fracture.
IMPORTANT! The leakage seal (39) with its ø3mm bores must be positioned onto the notched pins (35A) situated on the
seal sleeve (35). Make sure the cut-outs in the leakage seal are placed exactly over the bores of the seal sleeve (35)
and that the drip return bores in the valve casing (45) are also free to thus ensure trouble-free drip return.
12) Evenly tighten nuts (47) evenly at 59 ft.-lbs. (80 Nm) to x the valve casing (45).
DISASSEMBLY OF CRANKCASE
13) Remove valve casing (43) and plunger pipe (28B); drain oil.
14) Remove gear cover (4) and bearing cover (14).
15) Remove connecting rod screws (24A) and push the front of connecting rod forward as far as possible.
IMPORTANT! The connecting rods are marked for identication. Do not twist connecting rod halves. The connecting
rods mujst be remounted on to the shaft journals in their exact original position.
16) Turning the crankshaft (22) slightly, carefully hit on side of crankshaft with a rubber mallet until crankshaft is loose.
IMPORTANT! Do not bend the connecting rod shanks. Check the crankshaft and connecting rod mounting surfaces as
well as the shaft seal rings and roller bearings. Check crankshaft and bearing for damage, replace if needed.
REASSEMBLY
17) Using a soft tool, press in the outer bearing ring (20) until the outer edge lines up with the outer edge of crankcase
(1). Attach bearing cover (14) with shaft seal (15) and o-ring (16) in place. Fit crankshaft (22) through bearing hole
on the opposite side. Press in bearing with bearing cover, keeping the shaft in a horizontal position and turning it
slowly so that taper rollers touch the edge of outer bearing ring.
18) Adjust axial bearing clearance to at least .004” (0.1mm) and maximum at .006” (0.15mm) by placing tting discs (20A
& 20B) under the bearing cover (14).
IMPORTANT! After assembly, the shaft should turn easily with very little clearance.
19) Bolt connecting rod (24) halves together making sure they are replaced in the same position from which they came
from. Tighten connecting rod screws to 22 ft-lbs. (30 Nm).
6

Model LP650 Dimensions - Inches (mm)
7

GIANT INDUSTRIES, INC., 900 N. Westwood Ave., Toledo, Ohio 43607
PHONE [phone] FAX [phone] www.giantpumps.com
 Copyright 2021 Giant Industries, Inc. 09/21 LP650.indd
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. Five (5) years from the date of shipment for all pumps used in portable pressure
washers with NON-SALINE, clean water applications.
2. Two (2) years from the date of shipment for Giant pumps used in car wash
applications.
3. One (1) year from the date of shipment for all other Giant industrial and
consumer pumps.
4. Six (6) months from the date of shipment for all rebuilt pumps
5. 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 modications made by the customer or third party.
6. The operation of pumps and or accessories exceeding the specications 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 REPRESENTATION, 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.
WARNING: This product might contain a chemical known to the State of California to cause
cancer, and birth defects or other reproductive harm.
For more information go to www.P65Warnings.ca.gov