QF-450 PE & Gear Reducer Assy
QF-450 PE & Gear Reducer Assy
QF-450 PE & Gear Reducer Assy
QF-450
98-01003
Rev. - B
September 2006
QF-450 POWER END ASSEMBLY
17 Troubleshooting Guide
COPYRIGHT NOTICE:
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QF-450 POWER END ASSEMBLY
RECEIVING, INSPECTION
AND STORAGE WARNING:
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QF-450 POWER END ASSEMBLY
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QF-450 POWER END ASSEMBLY
Major Maintenance crankshaft end. Take care not in the up position. This will
to allow the crankshaft to drop allow lubrication oil to pass
as it passes through the through the power frame
Refer to Minor Maintenance
crankshaft bores in the power upper shelf and down to the
on previous page and the
frame. crosshead where it passes
Troubleshooting section on
With the crankshaft removed, through the crosshead pin
page 14 before proceeding.
the crosshead [8], the bearing. The oil also passes
connecting rod body [4] and thru a drilled hole running the
Disassembly Procedure entire length of the
the crosshead pin [7] can now
be removed from each power connecting rod [4] (part #70-
Remove the pump from the
frame bore as one complete 20004).
unit.
assembly per bore. Two styles of set screws are
Remove the oil drain plug and
The crosshead pin(s) [7] can used to secure the wrist pin
drain the crankcase oil.
now be removed from the [7] in the connecting rod wrist
Remove the hose clamp pin bore. These are dog point
crosshead [8] and connecting
securing the stub deflector. (sharpened) and cup end.
rod body [4] by first, removing
Loosen the plunger in the The dog point goes in first,
the two styles of set screws [6]
plunger adapter. This will the cup point is used following
- dog point (sharp) and [5] -
involve breaking a "Loc-tite" the dog point to lock the two
cup point (concave) and then,
bond on the threaded style in place. Snugly tighten both
pressing the crosshead pin out
plungers. The collet style with a "T" handle hex screw
of the crosshead bore. This
plungers require the use of a (Allen) key. The dog point set
can be done by hitting a wood
spanner wrench to loosen the screw should mate with an
peg placed on the end of the
collet nut. indentation in the crosshead
wrist pin or by hydraulic press.
Remove the two bolts [12] pin.
The wrist pin [7] and wrist pin
securing each of the If plunger adapters are
bushing can now be examined
diaphragm seal plates [11] in removed from the crossheads
for wear. The wrist pin should
their positions in the power [8], reinstall using Loc-tite 242
be replaced if it shows deep or
frame [1]. (medium strength, semi-
uneven wear. The wrist pin
Remove the diaphragm seal bushing can be replaced by permanent). Place a bead of
plates [11] (with their seals in pressing it out of the Loc-tite on the adapter
place), gaskets [10] and O- connecting rod wrist pin bore. threads and screw it into the
rings [9]. Note any lubrication holes in crosshead until it bottoms out.
the wrist pin bushing to allow Threaded plungers are to be
Remove the oil level indicator secured to the plunger
[40], elbows and nipples. and for proper re-assemble in the
same position in the adapters in the same manner.
the 28 hex head screws [32] Make certain the shoulder
securing the crankcase cover connecting rod bore.
between the plunger adapter
[33] to the power frame[1]. and plunger is clear of any
Push the crosshead(s) [8] Assembly Procedure obstruction to allow a clean
with the connecting rod [4] shoulder-to-shoulder match.
bodies in place as far forward Before the power end This avoids any potential
as required to clear the assembly is rebuilt, it should alignment problem between
operating area for the be thoroughly cleaned. High the adapter and the plunger.
crankshaft [2]. pressure water may be used if
Check the torque and
available. Wipe all ledges on
Remove both the gear box [3] lubrication specifications for
the inside of the frame to
(See Gear Box instructions) proper bolt torque values plus
remove any accumulated
and the gear pump. Then type and quantity of
deposits. Spray all exposed
remove the six hex head crankcase oil (page 4).
metal surfaces with WD-40 to
screws [27] securing the seal
avoid flash rusting. Magnets
end cap [29]. Leave the
should be wiped clean of all
crankshaft shim sets [30] (the
metal shavings that have
multi-colored plastic rings)
accumulated.
intact with the caps for re-
assembly. Performing the following
assembly process is a reversal
The crankshaft can now be
of the preceding disassembly
removed from either side by
procedure. Position the
tapping with a hammer and a
crossheads [8] in their power
wood block place on the
frame bores with the lube port
98-01003 Gardner Denver
REV. B Water Jetting Systems, Inc.
September 2006 Houston, TX USA
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QF-450 POWER END ASSEMBLY
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QF-450 POWER END ASSEMBLY
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QF-450 POWER END ASSEMBLY
WARNING
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QF-450 POWER END ASSEMBLY
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QF-450HB POWER END ASSEMBLY
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.
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QF-450HB POWER END ASSEMBLY
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.
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QF-450HB POWER END ASSEMBLY
Fig. 8 Power End Oil Lubrication System Kit – Part Number 4841000
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QF-450HB POWER END ASSEMBLY
`
98-01003 Gardner Denver
REV. B Water Jetting Systems, Inc.
September 2006 Houston, TX USA
13
QF-450HB POWER END ASSEMBLY
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.
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QF-450HB POWER END ASSEMBLY
W=.750 H=.500
L=3.500 KEY
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QF-450HB POWER END ASSEMBLY
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
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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.
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.
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QF-450HB POWER END ASSEMBLY
Pump Model:
Pump Serial Number:
Fluid End Assembly Drawing No:
Power End Assembly Drawing No:
Date Installed:
Maintenance Performed:
Describe Work:
Comments:
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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: [email protected]
98-01003
REV. B
September 2006