Instruction & Operation Manual

Q-450S
Fluid End Assembly

987078675
Rev. - I.R.
June 2004
 GENERAL INTRODUCTION:
HOW TO CONTACT:
This manual covers the TABLE OF CONTENTS:
If you need additional Quintuplex Q-450S Fluid End
information about your high Assembly which is mounted
pressure pump power end Page Description
on the QF-450 Power End.
assembly that is not included
in this manual, please contact This manual must be 2 General Introduction
customer service at: supplemented by other
manuals and training
materials to ensure that all 3 Receiving, Inspection and
operators sufficiently Storage
Gardner Denver Water understand how to use this
Jetting Systems, Inc. high pressure equipment 4 Minor Maintenance & Power
safely. End Lube Specifications
12300 North Houston-Rosslyn Rd
Houston, Texas 77086 Consult the power end 5 Major Maintenance &
manual for maintenance, dis - Assembly Procedure
Phone: 281 448-5800 assembly, assembly, trouble-
Fax: 281 448-7500 shooting and recommended 6 Power End Assembly Drawing
spare parts.
Toll Free: 800 231-3628 7 Power End Assembly BOM

8 Torque Specifications
E-mail:
sales@gardnerdenver.com
9 Oil Circulation System Photos

Additional copies of this 10 Oil Circulation System BOM

manual may be obtained from
customer service.
11 Oil Circulation System Photos

12 Gear Box BOM & Drawing

13 Recommended Spare Parts &

Abbreviations

14 Troubleshooting Guide

15 Pump Maintenance Log

COPYRIGHT NOTICE:

All rights are reserved under

International and Pan-
American Copyright
Conventions. No portion of
this manual may be copied
or reproduced without
written permission from
Gardner Denver WJSI.

98-01011 Gardner Denver

REV. I.R. Water Jetting Systems, Inc.
April 2004 Houston, TX USA
 Q-450S Fluid End Maintenance
(Reference Drawing D70-78675)

Fluid End Specification:

Quintuplex, 2 plungers x 4.5” stroke

Max. Pressure: 10,000 PSI
Max. Flow rate: 150 GPM
Service: Fresh or Sea-Water up to 180 F Degrees
Power End: Gardner Denver QF-450
NPSHR: 15 FT at max. flow rate

Safety:

1. Relief valve and safety head (rapture disk) shall be used. The fluid end has a
provision for built-in safety head. The safety head shall fail at approximately
150% of the working pressure and the relief valve shall be set to about 15%-
20% above the working pressure.

2. All nuts and screws shall be properly torqued as specified on the assembly
drawing .

3. Any high-pressure leakage shall be repaired immediately. Delaying of repair

will increase the amount of damage.

4. Failure to follow the above rules may result in property damage and body
injures or death.
Fluid End Assembly:

1. Install the three stuffing boxes [17] in the power end face in a way that the
packing lubricating holes will be at the top.

2. Install the all the components in the stuffing boxes as shown, install the gland
nut [15] but do not screw it all the way yet. Install the O-rings [9] in the C’bore
of the stuffing boxes.

3. Lubricate the threads and insert the twelve screws [12] through the adapting
plate [13].

4. Attach the three fluid cylinders blocks [19] to the stuffing boxes [17].

5. Tighten the 12 screws [12] just enough to hold the fluid cylinders [19] against
the stuffing boxes [17], but do not torque them yet.

6. Insert the o-rings [6] and [4] and the backup ring [5] into the grooves of the
valve assemblies [8].

7. Place three valve assemblies [8] on the top of the fluid cylinder [19] as shown.

8. Install the discharge manifold [7] over the three valve assemblies so that the
rupture disk port will be towards the power end (to the rear) as shown.
9. Lubricate the threads and insert the twelve screws [11] through the top of the
discharge manifold [7] and torque them as indicated in the drawing to the
maximum value.

10. Now torque the twelve screws [12] that hold the fluid cylinders [19] to the
power end.

11. Insert the plungers [21] (if not done yet) from the front and tighten it to the
plunger adapter [20] with the collet nut [22], then firmly tighten the gland nut
[15].

12. Install the remaining of the valve assemblies [8] in the fluid cylinders [19] as
shown.
Use two or three of the studs [37]* and insert them to any of the threaded holes
in the front of the fluid cylinders.
13. Install the suction manifold [3] over the studs [37] and against the valves [8].
Lubricate the twelve screws [1] and insert them through the manifold. Replace
the studs [37] with the remaining of the screws [1]. Torque the twelve screws
[1] as indicated in the drawing
Adding the accessories:
1. Insert the o-rings [32] into the discharge flange [36], use the four screws [33]
with each adapter and attach them to the discharge manifold [7]. Torque as
indicated.

2. Insert the o-rings [30] into the suction flange [19], use four screws [37] with
each adapter and attach them to the suction manifold[17]. Torque as
indicated.

3. Install the rupture disk in the discharge manifold [7]. Tighten the safety head
body firmly against the rupture disk and then install the safety head cap .
 PARTS LIST
ITEM QTY P/N DESCRIPTION
0 0 70-78675 KIT, FLUID END ASS Y QF-450S
1 20 16-77930 BOLT, SHCS, 7/8-9 X 8
2 20 16-77940 WASHER, HARDENED ROUND FLAT, 7/8
3 1 70-78676 MANIFOLD, Q-450S, SUCTION
4 10 22-33031 O-RING, 2 1/4, 2-226-90, OVERSIZE
5 1 70-78677 MANIFOLD, Q-450S, DISCHARGE
6 10 22-80284 O-RING, 2 5/8, 2-143-90
7 10 22-80285 BACK-UP RING, 2 5/8, 8-143
8 10 70-66204 VALVE, T-450S, SUCTION/DISCHARGE
9 10 22-20228 O RING, 2 7/8, 2-231-90
11 20 16-78508 SCREW, SHC, 7/8-9 X 6 1/2
12 20 16-77935 SCREW, SHCS, 7/8-9 X 5 1/2
13 1 70-78603 PLATE, ADAPTING, QF-450S
15 5 70-55008 PACKING GLAND
17 5 70-66014 STUFFING BOX
18 20 16-77937 WASHER, EXTERNAL TOOTH, 7/8
19 5 70-66203 CYLINDER, T-450S, FLUID
27 5 12-78003 TOOL, INSTALLATION
28 1 12-78005 WRENCH,SPANNER
29 2 70-80118 FLANGE, SUCTION MANIFOLD
30 2 22-80179 O-RING, 4, 2-240-70,
31 8 16-40002 BOLT, HE X HD, 3/8-16 1 3/4 #5
32 2 22-74207 O-RING, 1-1/2, 2-218-90
33 8 16-77111 BOLT, SHCS, 1/2-13 X 2
36 2 70-78604-001 ADAPTER, MANIFOLD, 1 NPT
37 4 16-78644 STUD, B-7, 7/8-9 X 15
38 1 16-78514 EYE BOLT, 1/2-13 X 1 1/2 THREADED
39 1 70-66211 ADAPTER, T-450S EYE BOLT
40 4 16-78645 SCREW, SHC, 1/4-20 X 5/8
43 5 70-20864 BUSHING, 1 1/4, ADAPTER, PLUNGER, UNIVERSAL
N.S. 1 12-78033 TOOL, VALVE SEAT REMOVAL
ITEM QTY P/N DESCRIPTION
0 0 70-78675-001 FLUID END ASS Y QF-450S W/ 1 1/2 PLUNGERS
14 5 70-66007-500 RING, LANTERN 1 1/2
20 5 70-20861 ADAPTER, PLUNGER, UNIVERSAL
21 5 70-80201-206 PLUNGER, 1 1/2, COLLET, COLMONOY
22 5 70-20863 SHORT NUT, ADAPTER, PLUNGER, UNIVERSAL
23 10 70-66005-500 BUSHING, THROAT 1 1/2
24 5 25-78002 SPRING, PACKING
25 5 70-66006-500 RING, FRONT PACKING 1 1/2
26 5 22-80104-002 PACKING, 2 3/8 X 1 1/2
A 1 70-78675 KIT, FLUID END ASS Y QF-450S

ITEM QTY P/N DESCRIPTION

0 0 70-78675-002 FLUID END ASS Y Q-450S W/ 1 5/8 PLUNGERS
14 5 70-66007-700 RING,LANTERN 1 5/8
20 5 70-20861 ADAPTER, PLUNGER, UNIVERSAL
21 5 70-80201-406 PLUNGER, 1 5/8, COLLET, COLMONOY
22 5 70-20863 SHORT NUT, ADAPTER, PLUNGER, UNIVERSAL
23 10 70-66005-700 BUSHING, THROAT 1 5/8
24 5 25-78002 SPRING, PACKING
25 5 70-66006-700 RING, FRONT PACKING 1 5/8
26 5 22-80104-003 PACKING, 2 3/8 X 1 5/8
A 1 70-78675 KIT, FLUID END ASS Y QF-450S

ITEM QTY P/N DESCRIPTION

0 0 70-78675-003 FLUID END ASS Y Q-450S W/ 1 3/4 PLUNGERS
14 5 70-66007-900 RING, LANTERN 1 3/4
20 5 70-20861 ADAPTER, PLUNGER, UNIVERSAL
21 5 70-80201-606 PLUNGER, 1 3/4, COLLET, COLMONOY
22 5 70-20863 SHORT NUT, ADAPTER, PLUNGER, UNIVERSAL
23 10 70-66005-900 BUSHING, THROAT 1 3/4
24 5 25-78002 SPRING, PACKING
25 5 70-66006-900 RING, FRONT PACKING 1 ¾
 26 5 22-80104 PACKING, 2 3/8 X 1 3/4
A 1 70-78675 KIT, FLUID END ASS Y QF-450S

ITM QTY P/N DESCRIPTION

0 0 70-78675-004 FLUID END ASS Y Q-450S W/ 1 7/8 PLUNGERS
14 5 70-66007-110 RING LANTERN 1 7/8
20 5 70-20861 ADAPTER, PLUNGER, UNIVERSAL
21 5 70-80201-806 PLUNGER, 1 7/ 8, COLLET, COLMONOY
22 5 70-20863 SHORT NUT, ADAPTER, PLUNGER, UNIVERSAL
23 10 70-66005-110 BUSHING THROAT 1 7/8
24 5 25-78002 SPRING, PACKING
25 5 70-66006-110 RING, FRONT PACKING 1 7/8
26 5 22-80104-005 PACKING, 2 3/8 X 1 7/8
A 1 70-78675 KIT, FLUID END ASS Y QF-450S

ITEM QTY P/N DESCRIPTION

0 0 70-78675-005 FLUID END ASS Y Q-450S W/ 2 PLUNGERS
14 5 70-66007-130 RING LANTERN 2
20 5 70-20861 ADAPTER, PLUNGER, UNIVERSAL
21 5 70-80201-126 PLUNGER, 2 , COLLET, COLMONOY
22 5 70-20863 SHORT NUT, ADAPTER, PLUNGER, UNIVERSAL
23 5 70-66005-130 BUSHING, THROAT 2
24 5 25-78003 SPRING, PACKING
25 5 70-66006-130 RING, FRONT PACKING 2
26 5 22-80104-006 PACKING, 2 3/8 X 2
A 1 70-78675 KIT, FLUID END ASS Y QF-450S