Instruction & Operation Manual

QF-450

Power End & Gear Reducer Assembly

98-01003
Rev. - B
September 2006
QF-450 POWER END ASSEMBLY

HOW TO CONTACT: TABLE OF CONTENTS:

If you need additional GENERAL INTRODUCTION:

information about your high
pressure pump power end
assembly that is not included
in this manual, please contact
customer service at:
Gardner Denver Water
Jetting Systems, Inc.
12300 North Houston-Rosslyn Rd
Houston, Texas 77086
Phone: 281 448-5800
Fax: 281 448-7500
Toll Free: 800 231-3628
E-mail:
sales@gardnerdenver.com
Additional copies of this
manual may be obtained from
customer service.
Page Description
This manual covers the power
2 General Introduction
end and planetary gear box
assemblies for the Quintuplex
450 Power End. 3 Receiving, Inspection and
Storage
• QF-450 POWER END
4 Minor Maintenance & Power
• QF-450 PLANETARY End Lube Specifications
GEAR BOX
5 Major Maintenance &
Assembly Procedure
The power end assembly may
be utilized with a variety of
fluid end assemblies: 6 Power End Assembly Drawing
Q-450SB – 10,000 PSI W.P. 7 Power End Assembly BOM
Q-450HB – 20,000 PSI W.P. 8 Torque Specifications
This manual must be
supplemented by other 9 Frame Load Limits
manuals and training materials
to ensure that all operators 10 -11 Oil Circulation System Photos
sufficiently understand how to
use this equipment safely. 12 - 13 Oil Circulation System BOM
Consult the Fluid End 13 Oil Circulation System Photos
Assembly Manuals for
pressure ratings. The power 15 Gear Box BOM & Drawing
end manual only covers
maintenance, disassembly,
assembly, troubleshooting and 16 Recommended Spare Parts &
recommended spare parts. Abbreviations

17 Troubleshooting Guide

18 Pump Maintenance Log

COPYRIGHT NOTICE:

All rights are reserved under Drawing Reference List:

International and Pan-
American Copyright Drawing No. Description
Conventions. No portion of
this manual may be copied or 70-41000 QF-450 POWER END ASSEMBLY
reproduced without written
permission from Gardner 64-46000-420 GEARBOX, PLANETARY – 500 HP, 4.20:1 RATIO
Denver WJSI.
48-41000 LUBRICATION SYSTEM KIT, QF-450 POWER END

98-01003 Gardner Denver

REV. B Water Jetting Systems, Inc.
September 2006 Houston, TX USA

2
QF-450 POWER END ASSEMBLY

RECEIVING, INSPECTION
AND STORAGE WARNING:

The power frame is shipped Power End is normally shipped with

on a heavy duty wood pallet a dry crankcase to comply with ICC
to prevent damage during transportation regulations.
shipping. It should be
similarly protected during Verify that proper lubricant has
subsequent handling and been added before the power end
storage. Always keep all assembly is operated. Failure to do
ports plugged to prevent this will cause severe mechanical
intrusion of foreign materials. damage to all internal components.
When you receive the power See Power End Lubrication
frame assembly, it should Specifications on page 4.
immediately be inspected
visually. If there are
indications of physical
damage, report this to the
carrier.
The power end assembly
should be left on the pallet
until it is to be mounted on the Power End Assembly
skid or unit. It should be Weight: 3500 lbs.
handled by one of the
following means:
• Overhead crane with
slings hung around the
planetary gear box and
the front of the frame.
• Tow Motor with forks
extended from the front
of the frame completely
under the crankcase.
It should be stored in a clean
environment until it is to be
mounted on a skid. If it is to
be stored for an extended
period of time, check with the
factory for recommendations.

98-01003 Gardner Denver

REV. B Water Jetting Systems, Inc.
September 2006 Houston, TX USA

3
QF-450 POWER END ASSEMBLY
Minor Maintenance
Cleaning and oil changing
should be performed on the
pump’s power end after the
initial 100 hours of operation
and every 500 hours or three
months thereafter.
Remove the power end drain
plug and drain the oil.
Remove the 28 hex head
screws [32] securing the
crankcase cover [33] to the
power frame housing [1].
Remove the crankcase cover
[33] and the cover gasket
[34]. It is recommended that
the gasket be replaced at this
time.
Wipe the crankcase clean using
a clean cloth soaked in solvent.
The magnets glued to the bottom
of the power frame should be
cleaned of any debris.
Check the torque on the
connecting rod bolts and
tighten if necessary.
Visually inspect the tapered
roller bearings [39], using a
flashlight and a mirror, for any
signs of excessive wear or
overheating. Replace the
bearings if this has occurred.
Remove the two bolts for
each connecting rod
assembly. The rod caps are
matched to the rod bodies
(see stamped ID numbers on
sides of rod cap and rod
body). Match these
components when the power
end is re-assembled.
The removal of the
connecting rod caps exposes
the connecting rod bearings
[38]. The rod bearings are
wear parts and should be
changed every 1000 hours, or
sooner if they show signs of
wear. The bearings are
copper based with a babbitt
coating.
98-01003
REV. B
September 2006
Note that if the overplate on
the bearings shows small
areas of copper exposed,
they do not need to be
replaced. A small amount of
this type of wear in is
normal during the break-in
period. Do not let the
bearing wear through to the
next layer.
They contain oil channels and
holes designed to align with
the holes in the connecting
rods. Note the hole placement
to allow for exact re-assembly.
The bearings are wearing
properly if they are smooth
with no ridges or deep
grooves. If grooves or uneven
wear are obvious, it may
indicate that the pump has
been overloaded (power
output too high) or the oil may
be contaminated.
Reinstall the crankcase gasket
[34], cover [33] and drain plug.
Refill the crankcase with the
recommended amount of gear
oil. See Power End Lubrication
Specifications.
Oil Change Interval:
• Initial change on new
pump after 100 hours.
• After the break in period,
every 500 hours of
operation or 3 month
interval, whichever comes
first. Keep a maintenance
log on every pump by
serial number.
Maintenance Tips for
Maximum Pump Life:
• Keep the oil level full and
clean.
• Keep water out of the oil.
• Change oil according to
schedule.
• Do not operate the pump
on an incline. This may
damage certain portions
of the pump and will void
the warranty.
4
• Do NOT operate the
power end below 200
RPM without forced feed
lubrication system. Con-
sult factory for specifica-
tions.
Power End Lubrication
Specifications:
Oil Capacity: 12 Gallons
Oil Type: API GL5 80W90
Note:
Oil capacity is provided as an
approximate value. The bottom
rollers of the main bearing are to be
covered in oil and the High Level
Alarm set slightly above this.
Warning: Oil selection is based
on ambient temperature range from
32o – 120o F.
CAUTION
Dirty oil, low oil level, and
improperly tightened bolts can
greatly shorten the life of your
pump. Bolt torque specifications
and other threaded connections
should be checked weekly. See
table on page 8 for torque values
and assembly drawing on page 6
for location of fasteners.
Lubrication Pump
Specification:
Power end oil lubrication pump
must be capable of delivering 20
GPM @ a maximum pressure of
200 PSI. Normal operating
conditions range from 80 – 120
PSI at temperatures up to 180o F.
A self- priming pump is
recommended.
Warning: The lubrication pump
must provide that output when the
QF-450 pump is operating under
loaded conditions, regardless of
driver RPM.
Gardner Denver
Water Jetting Systems, Inc.
Houston, TX USA
QF-450 POWER END ASSEMBLY

Major Maintenance
Refer to Minor Maintenance
on previous page and the
Troubleshooting section on
page 14 before proceeding.
Disassembly Procedure
Remove the pump from the
unit.
Remove the oil drain plug and
drain the crankcase oil.
Remove the hose clamp
securing the stub deflector.
Loosen the plunger in the
plunger adapter. This will
involve breaking a "Loc-tite"
bond on the threaded style
plungers. The collet style
plungers require the use of a
spanner wrench to loosen the
collet nut.
Remove the two bolts [12]
securing each of the
diaphragm seal plates [11] in
their positions in the power
frame [1].
Remove the diaphragm seal
plates [11] (with their seals in
place), gaskets [10] and O-
rings [9].
Remove the oil level indicator
[40], elbows and nipples. and
the 28 hex head screws [32]
securing the crankcase cover
[33] to the power frame[1].
Push the crosshead(s) [8]
with the connecting rod [4]
bodies in place as far forward
as required to clear the
operating area for the
crankshaft [2].
Remove both the gear box [3]
(See Gear Box instructions)
and the gear pump. Then
remove the six hex head
screws [27] securing the seal
end cap [29]. Leave the
crankshaft shim sets [30] (the
multi-colored plastic rings)
intact with the caps for re-
assembly.
The crankshaft can now be
removed from either side by
tapping with a hammer and a
wood block place on the
98-01003
REV. B
September 2006
crankshaft end. Take care not
to allow the crankshaft to drop
as it passes through the
crankshaft bores in the power
frame.
With the crankshaft removed,
the crosshead [8], the
connecting rod body [4] and
the crosshead pin [7] can now
be removed from each power
frame bore as one complete
assembly per bore.
The crosshead pin(s) [7] can
now be removed from the
crosshead [8] and connecting
rod body [4] by first, removing
the two styles of set screws [6]
- dog point (sharp) and [5] -
cup point (concave) and then,
pressing the crosshead pin out
of the crosshead bore. This
can be done by hitting a wood
peg placed on the end of the
wrist pin or by hydraulic press.
The wrist pin [7] and wrist pin
bushing can now be examined
for wear. The wrist pin should
be replaced if it shows deep or
uneven wear. The wrist pin
bushing can be replaced by
pressing it out of the
connecting rod wrist pin bore.
Note any lubrication holes in
the wrist pin bushing to allow
for proper re-assemble in the
same position in the
connecting rod bore.
Assembly Procedure
Before the power end
assembly is rebuilt, it should
be thoroughly cleaned. High
pressure water may be used if
available. Wipe all ledges on
the inside of the frame to
remove any accumulated
deposits. Spray all exposed
metal surfaces with WD-40 to
avoid flash rusting. Magnets
should be wiped clean of all
metal shavings that have
accumulated.
Performing the following
assembly process is a reversal
of the preceding disassembly
procedure. Position the
crossheads [8] in their power
frame bores with the lube port
in the up position. This will
allow lubrication oil to pass
through the power frame
upper shelf and down to the
crosshead where it passes
through the crosshead pin
bearing. The oil also passes
thru a drilled hole running the
entire length of the
connecting rod [4] (part #70-
20004).
Two styles of set screws are
used to secure the wrist pin
[7] in the connecting rod wrist
pin bore. These are dog point
(sharpened) and cup end.
The dog point goes in first,
the cup point is used following
the dog point to lock the two
in place. Snugly tighten both
with a "T" handle hex screw
(Allen) key. The dog point set
screw should mate with an
indentation in the crosshead
pin.
If plunger adapters are
removed from the crossheads
[8], reinstall using Loc-tite 242
(medium strength, semi-
permanent). Place a bead of
Loc-tite on the adapter
threads and screw it into the
crosshead until it bottoms out.
Threaded plungers are to be
secured to the plunger
adapters in the same manner.
Make certain the shoulder
between the plunger adapter
and plunger is clear of any
obstruction to allow a clean
shoulder-to-shoulder match.
This avoids any potential
alignment problem between
the adapter and the plunger.
Check the torque and
lubrication specifications for
proper bolt torque values plus
type and quantity of
crankcase oil (page 4).
Gardner Denver
Water Jetting Systems, Inc.
Houston, TX USA

5
QF-450 POWER END ASSEMBLY

Fig. 1 – Power End Assembly (Side View) (Above)

Fig. 2 – Power End Assembly w/ Gear Box – Top View (Below)

98-01003 Gardner Denver

REV. B Water Jetting Systems, Inc.
September 2006 Houston, TX USA

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QF-450 POWER END ASSEMBLY

Item Qty. Part No. Description

0 0 7041000 KIT, POWER END, QF-450 W/ PLANETARY GEAR BOX
1 10 1675658 BOLT, HXHD, CDPLT, 1/2-13 X 1 1/4
2 5 7020009 PLATE, DIAPHRAGM SEAL
3 15 2220002 SEAL, DIAPHRAGM SEAL PLATE OIL
4 2 1615442 DOWEL PIN 1/2DIA X 1-1/2 LG
5 1 7040001 POWER FRAME QF-450 MACHINED
6 5 2220015 O-RING, 6 1/4
7 5 7020003 CROSSHEAD-2000 PUMP
8 5 7045006 PIN, CROSS HEAD
9 5 1615440 SCREW, SET, 1/2-13 X 1/2, HALF DOG
10 5 1615439001 SCREW, SET, LOCK, 1/2-13 X 1/2 CUP POINT
11 6 1615058 BOLT, HXHD, BLACK, GRADE 8, 3/4-10 X 2 1/2
12 1 1990610 ADAPTER STRT 8 MALE O-RING X 5/8-18UNF ASSY
13 28 1615212 BOLT HXHD ZINC PLT GR5 3/8-16 UNC X 3/4
14 1 7040011 COVER, CRANKCASE
15 1 7041002 CRANKSHAFT, SPLINED, QF-450
17 2 1640004 RETAINING RING, EXTERNAL
18 2 5240044 RADIAL CENTRAL SUPPORT BEARING
19 2 1640003 RETAINING RING, INTERNAL
20 2 1677927 STUD, 1-1/4 - 7 X 17 1/2 LONG
21 5 7020004100 ROD, FORCED OIL QUINTUPLEX CONNECTING
22 1 2240003 GASKET, CRANKCASE COVER QF450
23 1 7040008200 CAP, SEAL END, TX-450
24 6 1615054 BOLT, HXHD, 3/4-10 X 2
25 1 4841000 KIT, LUBRICATING SYSTEM, QF-450 POWER END
26 1 2220012 SHAFT SEAL, OIL, TX-450
27 1 3540242001 UNION ROTARY SIZE 3/8 SS GENERAL PURPOSE
28 2 5240041 BEARING, CRANKSHAFT
29 2 2240005 SHIM SET - 14.15/16 OD
30 2 1900370 PIPE PLUG,1-1/2 IN NPT
31 4 1933283 PIPE PLUG 3/4 NPT
32 4 1615025 BOLT, HXHD, 1/4-20 X 1/2
33 1 7040010 WELL COVER
34 8 1615441 NUT, HEX, 1 1/4-7
35 6 1645002 STUD 1 1/4-7 UNC X 6.5 LG
36 1 1933252 BUSHING 1 1/2INX3/4 NPT BRASS
37 1 1932023001 BUSHING 3/4 IN X 1/2 NPT BRASS
38 1 7075515 BREATHER 1/2 NPT POWER END
39 2 3777082 GAUGE OIL LEVEL NON-THREADED HOLE 1 7/8
40 2 2280278 O-RING, 1 7/8
41 2 1977014 PIPE PLUG, 1 NPT, SQUARE HEAD
44 1 1933220 BUSHING 1 X1/2 NPT MAL. IRON
45 10 7002355 MAGNET, POWER END
46 5 7020021100 BEARING, QUINTUPLEX CONNECTING ROD
48 2 7040015 SPACER, BOLT

98-01003 Gardner Denver

REV. B Water Jetting Systems, Inc.
September 2006 Houston, TX USA

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QF-450 POWER END ASSEMBLY

49 2 1990562 ADAPTER, 1 MNPT X 1 1/4 MNPT

Item Qty. Part No. Description
50 1 1990564 PLUG HEX 1 1/4 NPTM PLTD
51 1 5530055 VALVE, CHECK, 1 1/4 NPT, GRAVITY LIFT, BRZ
52 1 1990595 TEE 1 1/4 NPTF (2X) X 1 1/4 NPTM RUN PLTD
53 1 66VBB16000 BALL VALVE 1 NPT BRASS
54 1 1977014 PIPE PLUG, 1 NPT, SQUARE HEAD

Fig. 3 – Diaphragm Seal Plate

TORQUE SPECIFICATIONS: POWER END ASSEMBLY

ITEM QTY. DESCRIPTION THREAD SIZE TORQUE

1 10 CAPSCREW, DIAPHRAGM SEAL PLATE 1/2” – 13 UNC 35 FT. LBS.
13 28 CAPSCREW, REAR COVER GASKET 3/8” – 16 UNC 25 FT. LBS.
21 10 SHCS – CONNECTING ROD ½” – 13 UNC 85 FT. LBS.
28 6 CAPSCREW, SEAL END PLATE ¾” – 10 UNC 150 FT. LBS.
28 6 CAPSCREW, GEAR REDUCER HOUSING ¾” – 10 UNC 150 FT. LBS.

34 4 STUD – ADAPTING PLATE TO FRAME 1 1/4”- 7 UN 500 FT. LBS.

N.S. 4 BOLT, HXHD, 1 1/4 -7 X 4 ½ POWER FRAME TO 1 1/4 –7 UNC 250 FT. LBS.
PUMP MOUNT

WARNING

Proper torque is very important to prevent stud failure.

Refer to assembly drawings (Fig. 1 & 2) on page 6 for
fastener location.

98-01003 Gardner Denver

REV. B Water Jetting Systems, Inc.
September 2006 Houston, TX USA

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QF-450 POWER END ASSEMBLY

FRAME LOAD LIMITATIONS: SINGLE-SPEED UNITS

FLUID END ASSY. PLUNGER MAX. PRESSURE RATING CAUTION

QF-450 HB 1.06” 20,000 PSI The power end assembly can be

QF-450 HB 1.19” 15,000 PSI damaged if the frame load is
exceeded.
QF-450 HB 1.25” 14,000 PSI
QF-450 HB 1.38” 11,500 PSI The rated frame load is based on
the fluid end assembly and the
QF-450 SB 1.63” 8500 PSI maximum pressure rating for a
QF-450 SB 1.75” 7500 PSI specific plunger size.
QF-450 SB 1.88” 6500 PSI
QF-450 SB 2.00” 5500 PSI
QF-450 SB 2.13” 5000 PSI

FRAME LOAD LIMITATIONS: MULTI- SPEED UNITS

FLUID END ASSY. PLUNGER MAX. PRESSURE RATING

QF-450 HB 1.06” 25,000 PSI

QF-450 HB 1.19” 22,500 PSI
QF-450 HB 1.25” 20,000 PSI
QF-450 HB 1.38” 16,500 PSI
QF-450 SB 1.63” 10,000 PSI
QF-450 SB 1.75” 10,000 PSI
QF-450 SB 1.88” 9000 PSI
QF-450 SB 2.00” 8000 PSI
QF-450 SB 2.13” 7000 PSI

98-01003 Gardner Denver

REV. B Water Jetting Systems, Inc.
September 2006 Houston, TX USA

9
 QF-450HB POWER END ASSEMBLY

Fig. 4 – Oil Circulation System

Oil lubrication assembly with

manifold, dual pressure gauges,
internal regulator, oil filter, &
dual oil level indicators. (Note
that indicators are available in
three options: sight glasses,
level indicator with exposed
terminals and level indicator with
conduit connection.

Fig. 5 – Lubrication Manifold

Oil lubrication manifold with dual

pressure gauges. The left gauge
indicates crankshaft lube pressure
and the right gear box supply.
The regulator is factory set to
provide between 80 – 120 PSI
supply to the crankshaft. It should
not normally need to be adjusted.
Likewise there is a flow adjustment
that distributes flow to the cross-
head guides and the gear box. It
is also set at the factory and does
not normally need to be adjusted
in the field.

WARNING:

The oil lubrication system does NOT include the lube pump for bare-shaft pumps or power end
assemblies. It is the responsibility of the end user to provide this pump according to the
specifications in this manual. Be sure that it provides the specified flow rate at the operating RPM
of the diesel engine or electric motor. Contact customer service if you have any questions regarding
the requirements. Failure to provide adequate lubricant flow and pressure can result in damage to
the crankshaft journals, connecting rod bearings, main bearings and other rotating or reciprocating
components in the power end assembly.

98-01003 Gardner Denver

REV. B Water Jetting Systems, Inc.
September 2006 Houston, TX USA

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QF-450HB POWER END ASSEMBLY

Fig. 6 – Oil Level Indicator & Shutdown Fig. 7 – Oil Filter

Oil Level Gauge provides visual indication of Hydraulic filter Cartridge with indicator;
the power end oil condition (level, color, foam, inspect the filter cartridge element
etc.) High and low contacts connect to the indicator to verify that the pressure drop
driver to shut the unit down in the event that across the cartridge is within the
the oil level drops below the minimum level or acceptable range. The cartridge should
rises above the maximum. The latter be changed with each oil change. See
condition can occur if water has contaminated lubrication schedule on page 4.
the power end.
Filter Cartridge Part No. - 4046001
Note that your unit may be equipped with
sight glasses or the level indicator with
exposed terminals. The unit shown has a
conduit connection for the wiring connection
to the driver shutdown system.

98-01003 Gardner Denver

REV. B Water Jetting Systems, Inc.
September 2006 Houston, TX USA

11
QF-450HB POWER END ASSEMBLY

Fig. 8 Power End Oil Lubrication System Kit – Part Number 4841000

Item QTY Part No. Description

0 0 4841000 KIT, LUBRICATING SYSTEM, QF-450 POWER END
1 1 4821000 KIT, LUBRICATION BOX, 450 PUMP
2 5 1990658 ADAPTER #6 JICM X 3/4 NPTM PLTD 90 DEG
6 2 77409155 6 JIC X 1/4 NPTM STR. FITTING
8 3 6140005 HOSE HYD 421-8 2000 PSI 1/2 ID
12 12 6140004 HOSE HYD 421-6 2250 PSI 3/8 ID
14 2 1990702 FITTING SWIVEL CRIMP STRT 8 JICF PLTD
16 1 1990598 ADAPTER STRT 8 JICM X 3/8 NPTM PLTD
17 10 1990701 FITTING SWIVEL CRIMP STRT 6 JICF PLTD
18 1 66JP080890 ADP 1/2 NPT X 1/2 JIC 9O DEG (FJP)

98-01003 Gardner Denver

REV. B Water Jetting Systems, Inc.
September 2006 Houston, TX USA

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QF-450HB POWER END ASSEMBLY

Fig. 9 - Power End Lubrication System Components – P/N 4821000

Item QTY Part No. Description

0 0 4821000 KIT, LUBRICATION BOX, 450 PUMP
1 4 1615212 BOLT HXHD ZINC PLT GR5 3/8-16 UNC X 3/4
2 1 4821110 BOX, LUBRICATION, 450 PUMP
3 1 7921101 MOUNT, LUBRICATING BOX, 450 PUMP
4 2 1990573 ADAPTER, 3/4-#8 JIC X 1/2 MNPT, S.S.
5 1 1901108 PIPE NIPPLE,1 X 8 LG. SCH 40, BLACK
6 1 4046002 HEAD ASSEMBLY, OIL FILTER, 1 NPT PORT
7 1 4046001 ELEMENT, OIL FILTER, 9 IN SYN
8 1 1990605 ELBOW 16 JICM X 1 NPTM PLTD
9 1 66JP080890 ADP 1/2 NPT X 1/2 JIC 9O DEG (FJP)
10 3 77409155 6 JIC X 1/4 NPTM STR. FITTING
11 2 77118006 PLUG. 1/4 NPT SS SOCKET HEAD
14 1 3777090 GAUGE 2-1/2 DIAL 0-600 PSI SS 1/4 NPT BOT CON
15 1 3732030 GAUGE,1/4NPT,2.5 FACE,0-200PSI
SWITCH PRESSURE 50 PSI FALLING 1/4 NPT NEMA
16 1 4640106 4
17 1 6142005 HOSE ASSY, 2000 PSI 1/2 ID, W/SWIVEL FITTING

`
98-01003 Gardner Denver
REV. B Water Jetting Systems, Inc.
September 2006 Houston, TX USA

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QF-450HB POWER END ASSEMBLY

Fig. 10– Oil Circulation System

Planetary Gear Box - Oil Circulation

Connection.

Lubrication to the gear box is flooded;

there is a ½” NPT drain port at the bottom
of the housing. (See drawing on p. 14)
Both this plug and the plug in the power
frame must be removed when draining the
oil. The R.H. gauge on the lube manifold
shows the pressure in the supply line. This
should be in 5 – 20 PSI range depending
on oil temperature.

Fig. 11 – Oil Distribution Hoses

Oil Lines from the bypass circuit flood the

crossheads and power frame cylinder
bores.

Oil Circulation System Operating Parameters:

Required Oil Flow Rate: 20 GPM

Crankshaft Lube Pressure: 80 - 120 PSI
Normal Operating Temperature: 160o – 180o F.
(Based on ambient temperature in 90 – 100o F. range)

Cold weather startup may result in higher oil system pressures until the viscosity of the oil
decreases as the power end temperature approaches the normal operating range.

Note: The planetary gearbox, crosshead and wrist pin areas of the pump power end have a
flooded lubrication system; only the journal bearings are pressurized. See additional
information regarding the oil pump specification on page 4.

98-01003 Gardner Denver

REV. B Water Jetting Systems, Inc.
September 2006 Houston, TX USA

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 QF-450HB POWER END ASSEMBLY

ITEM QTY. PART NO. DESCRIPTION

64-46000-420 GEAR BOX, PLANETARY, 4.2:1
1 1 64-46002 HOUSING, GEAR BOX, PLANETARY, 80 TOOTH RING
2 1 64-46001-420 KIT, PLANETARY GEAR SET, 4.20:1

Fig. 12 – Planetary Gearbox –

cross-section & end views

W=.750 H=.500
L=3.500 KEY

Gear Box Options

The following drive ratios

are available for the QF-
450 Series Pumps:

Ratio Part Number

3.35:1 6446000335
4.20:1 6446000420
4.64:1 6446000464
5.21:1 6446000521

OIL DRAIN HOLE

1/2'' - NPT THREAD

98-01003 Gardner Denver

REV. B Water Jetting Systems, Inc.
September 2006 Houston, TX USA

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QF-450HB POWER END ASSEMBLY

RECOMMENDED SPARE PARTS:

ITEM QTY. PART NO. DESCRIPTION

3 3 22-20002 SEAL, DIAPHRAGM SEAL PLATE OIL
4 1 40-46001 ELEMENT, OIL FILTER, 9 IN SYN
6 1 22-20015 O-RING, 6 1/4, 2-258-70
22 1 22-20003 CRANKCASE COVER GASKET
26 1 22-20012 SHAFT SEAL, OIL, TX-450
29 1 22-40005 SHIM SET - 14.15/16" OD

Shim Set Specifications: P/N 22-40005

Qty. Part Number Description

2 2240005003
2 2240005004
2 2240005005
2 2240005010
2 2240005020
.003” Thick, Green
.004” Thick, Tan
.005” Thick, Clear
.010” Thick, Brown
.020” Thick, Yellow

Note: If it is necessary to replace the shims or remove the crankshaft from the power frame, record the
quantity and color of the shims removed from each side. Normally it will be the same quantity on both sides.

ABBREVIATIONS:

ABBREVIATION DESCRIPTION
FTTNG FITTING (PIPE)
GSKT GASKET
HDWR HARDWARE (FASTENERS)
HHCS HEX HEAD CAPSCREW
I.R. INITIAL RELEASE
IND INDICATOR
NPT NATIONAL TAPER PIPE THREAD
NS NOT SHOWN
PE POWER END ASSEMBLY
PSI POUNDS PER SQUARE INCH
SHCS SOCKET HEAD CAPSCREW
S/N SERIAL NUMBER
WP WORKING PRESSURE

98-01003 Gardner Denver

REV. B Water Jetting Systems, Inc.
September 2006 Houston, TX USA

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QF-450HB POWER END ASSEMBLY

TROUBLESHOOTING GUIDE
PROBLEM INSPECTION SUGGESTED CORRECTIVE ACTION
(see notes below)
Power End Knocking - Audible sound Replace journal bearing.
Worn Journal Bearing
Power End Knocking - Audible sound Replace worn parts.
Worn wrist pin or bushing
Power End Knocking - Audible sound Replace shims and adjust to factory end play
Excessive end play in main roller setting.
bearings
Power End Knocking Audible sound Replace spring(s) – see Fluid End Manual, P/N
Broken or weak valve spring(s) 9901011.

Power End Knocking - Audible sound Fill crankcase according to recommendations

Low Oil Level listed on p. 4 of this manual.

Power End Knocking - Audible sound Increase water supply pressure to

Low Suction Supply Pressure
High Power End Temperature
(> 180o F or 82o C)
Oil Level too high
High Power End Temperature
(> 180o F or 82o C)
Poor air circulation in pump room
recommendations listed in Fluid End Manual,
P/N 9901011.
Temperature Drain crankcase oil level to recommendations
Monitoring listed on p. 4 of this manual.
Temperature Improve ventilation or insulate heat source to
Monitoring reduce the ambient temperature in the pump
room or environment.

High Power End Temperature Temperature Add oil to crankcase to recommendations listed
(> 180o F or 82o C) Monitoring on p. 4 of this manual.
Oil Level too low

Notes: To determine if the knocking sound is coming from the power end or fluid end of the pump, it may be
necessary to temporarily disconnect the plungers from the plunger adapter.

• Carefully push the plungers forward into the fluid cylinder until they reach a mechanical stop; do not
force them.
• Remove collet nuts and bushings from the plunger adapter. Momentarily start the driver and
immediately turn it off to verify that the pump will rotate through a complete stroke without hitting the
plungers.
• If the sound continues with the fluid end disconnected, the problem is in the power end.
• Open the rear crankcase cover to allow inspection of the journal bearings.
• Remove the seal end cap, Item 23, to inspect the shim set on the end opposite to the planetary
gearbox. If shims have experienced excessive operating temperatures, they may have extruded which
may allow excessive end play. Replace the shims.
• If shims are replaced on the non-driven end of the crankshaft, they should also be replaced between the
planetary gear and the power frame. It is recommended to consult the factory before performing this
maintenance.
• It is recommended that power end temperatures be routinely monitored using an infrared thermometer
and recorded in your maintenance log.

98-01003 Gardner Denver

REV. B Water Jetting Systems, Inc.
September 2006 Houston, TX USA

17
QF-450HB POWER END ASSEMBLY

Pump Maintenance Log:

Pump Model:
Pump Serial Number:
Fluid End Assembly Drawing No:
Power End Assembly Drawing No:
Date Installed:

Oil Change Performed by: Change Date:

Oil Specification: Gallons of Oil:

Power End Temperature Log: ___/___/___ ___/___/___ ___/___/___ ___/___/___ ___/___/___

Main Bearing – opposite to Gear

Main Bearing – adjacent to Gear
Crankcase – below oil level
Planetary Gearbox - Housing
Power Frame – above crossheads

Oil Change Performed by: Change Date:

Oil Specification: Gallons of Oil:

Power End Temperature Log: ___/___/___ ___/___/___ ___/___/___ ___/___/___ ___/___/___

Main Bearing – opposite to Gear

Main Bearing – adjacent to Gear
Crankcase – below oil level
Planetary Gearbox - Housing
Power Frame – above crossheads

Maintenance Performed:
Describe Work:

List Parts Changed:

Comments:

98-01003 Gardner Denver

REV. B Water Jetting Systems, Inc.
September 2006 Houston, TX USA

18
 Gardner Denver Water Jetting Systems, Inc.
12300 N. Houston Rosslyn Road
Houston, TX 77086
USA
Phone: 800) 231-3628
Fax: (281) 448-7500
E-Mail: mktg.wjs@gardnerdenver.com

98-01003
REV. B
September 2006