Product Manual - CDS
Contents
1. 74 1 DP 74 1 GRI 90 1 4 DP 90 1 GRI DIAPHRAGM PUMP Parts amp Instruction Manual CDS JOHN BLUE COMPANY DIVISION OF ADVANCED SYSTEMS TECHNOLOGY INC 165 Electronics Blvd Huntsville AL 35824 Telephone 256 721 9090 FAX 256 721 9091 Call Toll Free 1 800 253 2583 Printed in U S A 7 M 41 REV 10 14 SAFETY PRECAUTIONS e Equipment should be operated only by trained responsible people Acareful operator is the best insurance against an accident Fill system with WATER first and check output Check all valves fittings hose clamps etc for tightness and soundness before admitting fluid to system Replace hoses when worn cracked or if leaking WARNING USE OF THIS PRODUCT FOR ANY PURPOSES OTHER THAN ITS ORIGINAL INTENT ABUSE OF THE PRODUCT AND OR MODIFICATION TO THE ORIGINAL PRODUCT IS STRICTLY PROHIBITED BY CDS JOHN BLUE COMPANY CDS JOHN BLUE COMPANY RESERVES THE RIGHT TO DENY WARRANTY OR LIABILITY CLAIMS IN ANY ALL SITUATIONS INVOLVING MISUSE ABUSE OR MODIFICATION THE ORIGINAL INTENT OF THIS PRODUCT DOES NOT INCLUDE USE WHERE THE MAXIMUM ALLOWED SPEED PRESSURE OR TEMPERATURE IS EXCEEDED AND IT DOES NOT INCLUDE APPLICATION UTILIZING FLUIDS THAT ARE NOT COMPATIBLE WITH THE PRODUCT S COMPONENT MATERIALS DO NOT USE THIS PRODUCT WITH FLAMMABLE OR COMBUSTIBLE FLUIDS SUCH AS GASOLINE KEROSENE DIESEL ETC AND DO NOT USE IN EXPLOSIVE ATMOSPHERES FAILURE TO FOLLOW THIS NOTICE MAY RESU2. mw r gt BV TE PTE OCE EN a Gz p NG 472797793 925 WARRANTY 5 THIS WARRANTY IS IN LIEU OF ALL OTHER WRITTEN OR EXPRESS WARRANTIES AND REPRESENTA TIONS ANY IMPLIED WARRANTIES INCLUDING MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE ARE EXPRESSLY LIMITED TO THIS WRITTEN WARRANTY CDS JOHN BLUE COMPANY SHALL NOT BE LIABLE FOR CONSEQUENTIAL DAMAGES Use of this product for any purpose other than its original intent abuse of the product and or any modification to the original product is strictly prohibited by the manufacturer CDS John Blue Company Any modification to the product should be approved by CDS John Blue Company prior to use CDS John Blue Company will deny Warranty claims and liability in any situation involving misuse abuse or modification 455223 3 4 NE NE 82 9 0 69 6990 19 ved NONE xT Each new machine or component manufactured by CDS John Blue Company through original buyer is warranted by CDS John Blue Company to buyer and to any party or parties to whom buyer may resell lease or lend the equipment to be free from defects in material and workmanship under normal use and service This obligation of CDS John Blue Company under this warranty is limited to the repair or replacement of defective parts or correction of improper workmanship of any parts
3. 15 BAR NOB 1 N 5 2 3 4 5 0 1 7 6 7 U lt SC 24031951 OPPET 2 2 2 2 2 2 2 2 2 8 8 29 SC 24032132 14 05 DIVISION OF ADVANCED SYSTEMS TECHNOLOGY JOHN BLUE Telephone 256 721 9090 Fax 256 721 909 Call Toll Free 1 800 253 2583 TROUBLES AND CURES TROUBLES The pump doesn t reach the valves have worn seats check valves required pressure suction hose with air pockets or irregular elbows check hoses worn nozzles or with wrong diameter check nozzles see chart s zj trai Clogged strainer clean strainer The pressure gauge fluctuates pump is sucking air or air hasn t been evacuated completely start pump with the gun open to evacuate valves blocked the air and commutate clean and change valves The liquid flow is irregular the air in the pulsation damper is incorrectly set check pressure in pulsation damper see chart Output drops and the pump is oil level is too low top up with oil to correct level halfway of noisy the sump when pump 15 operating Oil comes out of the discharge one or more diaphragms are broken Drain the pump of oil Dismantle the head pipe and change diaphragms Fill to the correct oil level Oil is changing color into white Diaphragm failures Stop pump immediately Drain the pump of oil Dismantle the head and change diaphragms Fill to the correct oil level
4. Chart on the Service Manual The pressure regulator lever should be turned downward Whenever the by pass jet is used the pressure adjustment lever must be turned in the down position so that the pressure is zero Check to make sure the strainer is clean Be sure the cartridge is reinstalled and tightened to assure no suction leak Check for leaks Suction Head Do not use suction head for filling the tank Avoid suction head higher than 10 feet In this case some troubles may occur in the pump parts Operation Instructions Start pump and let run for approximately one minute at zero pressure to facilitate priming Once primed the pump is ready and can be set to run at the desired pressure by moving the lever downwards and turning the adjustment knob clockwise Operating pump above recommended rpm will not improve performance but rather may damage the pump Operation at rpm higher than specifications voids all warranties Working pressure should be selected with the discharge line closed and all liquid in by pass While the pump is running check the oil level in sight glass This acts as an emergency indicator to signal malfunction e g if the diaphragm breaks the oil will become white Stop the pump immediately Do not rotate the shaft for long periods without liquid in the cylinders or in the suction line If the pump 15 driven by a PTO shaft and sprayer makes a sharp turn disconnect the tractor PTO to preve
5. DP 86210800 DP 31891697 BALL BEARING SPACER CONROD RING SPACER SHAFT RING CONNECTING ROD PISTON PISTON RING PISTON PIN RING SCREW M10X16 COVER OIL SEAL SPACER CRANKSHAFT VERSION BALL BEARING PISTON SLEEVE SCREW M8X50 DIAPHRAGM WASHER SCREW KIT SAFETY VALVE OPT PLAIN SAFETY CONE OPT WASHER OPT SCREW OPT WASHER SCREW 6 16 KIT ITEM PART NUMBER DP 80212650 DP 80643600 DP 31079542 DP 81261600 PP 85351100 DP 86256600 DP 85351 100 DP 86321200 DP 31191409 DP 86256900 DP 31072942 DP 80308090 DP 82414100 DP 85262953 DP 31128509 DP 90 1 GRI 1 2137 11 27 SSO PARTS LIST FOR DP 90 1 GRI DESCRIPTION O RING 30X60X10 KEY PINION GEAR BALL BEARING OIL SIGHT GLASS SCREW 5 16 FILLER PLUG SCREW M10X20 GEAR BOX SELF LOCKING SCREW GEAR O RING 1 78X82 27 GASKET PLUG CENTERING FLANGE ENGINE GEAR BOX 13 0 PJ S 19 18 17 12 11 10 26 25 24 23 22 5 1132 2 Pressure Regulator 2 Outlets ITEM DESCRIPTION 1 VALVE HOUSING RESSURE GAUGE 0 100 BAR RESSURE GAUGE 0 24 BAR RING 0 DEGREE ELBOW CONN ING NUT EFT TAP 7 UTLET STRAIGHT PORT ING NUT IGHT TAP ASHER 1 1 12 13 SC 86241400 CREW SC 81452500 DP 80321800 RING 1 RING 16 ALVE SEAT 1 CREW 18 19 PS DIAPHRAGM ASHER CREW LANGE RING RING N UIDING PISTON EVER PRING 40 BAR PRING
6. Drain the oil from the pump by removing cap under the crankcase Rotate the shaft to remove excess oil Remove the pump heads one by one Use hex wrench to remove the diaphragm locknut remove the nut retaining washer diaphragm and support washer If you removed the piston sleeves replace them one at a time in their previous position best mark them when removing Insert the new diaphragm on the piston and install it with its nut Use these tightening torques 10 mm 236 ft Ibs 12 mm 50 ft Ibs 12 72 ft Ibs The diaphragms should be replaced with the piston at its bottom DP and the edges inserted perfectly into the groove all the way around Replace the heads and attach them with their bolts Refill pump with oil through the glass and rotate the shaft to distribute oil and fill to proper level Repeat all the checks described above in the section Checks to make before using the pump Check oil level with the pump running with no pressure until all air bubbles have been vented When the air has been bled off close the cap on the oil sight tube After the first inspection of the oil level as above check once more the oil level with the pump running with pres sure 3 Oil Change Normally the oil is changed whenever the diaphragm is changed Depending on work conditions oil should be changed every 500 hours The oil change procedure is described in number 2 above FOR
7. of such equipment which shall within one year from the date of CDS John Blue s original delivery thereof be returned to CDS John Blue s factory transportation charges prepaid and which CDS John Blue Company shall determine 0 its satisfaction upon examination thereof to have been thus defective When it is impractical to return the defective parts Pa of such equipment to CDS John Blue s factory then CDS John Blue shall have no liability for the labor cost imvolved m repairing or replacing any such parts and shall be liable solely for supplying the material necessary to replace repair the defective parts provided that prior thereto CDS John Blue Companv shall have determined to its satisfaction that anv such parts are thus defective This warranty shall not apply to any equipment which shall have been repaired or altered outside CDS John Blue s factory in any way so as to affect its durability nor which has been subjected to misuse abuse negligence or accident or operated in any manner other than in accordance with operating instructions provided by CDS John Blue Company This warranty does not extend to repairs made necessary by the use of inferior or unsuitable parts or accessories or parts or accessories not recommended by CDS John Blue Company k 4 8 14 27 1 4 g 18 OR MACA U 5 vg SE S I eee eee CDS John Blue Com
8. DP 03001161 DP 94004776 DP 03001261 DP 80133100 DP 03000509 DP 03000609 DP 81850250 DP 85200600 DP 80000300 DP 86318500 DP 17001361 DP 80226410 DP 03001561 DP 03001726 DP 03003826 DP 81293300 DP 03000701 DP 03003601 DP 86289300 DP 03002197 DP 24304097 DP 31148232 DP 84381000 DP 86321200 DP 84358500 DP 86210800 DP 31891697 DESCRIPTION SPACER CONROD RING SPACER SHAFT RING D 45 CONROD PISTON PISTON RING PISTON PIN RING DIA 10 SCREW M10X16 COVER OIL SEAL SPACER CRANKSHAFT VF VERSION CRANKSHAFT 212 VERSION BALL BEARING DIA 45X75X16 PISTON SLEEVE VERS VF amp VC PISTON SLEEVE VERS SCREW 8 50 KIT DIAPHRAGM WASHER SCREW SAFETY VALVE 40BAR OPT PLAIN SAFETY CONE OPT WASHER OPT SCREW 10 20 OPT WASHER SCREW 6 16 KIT QTY N N N ITEM PART NUMBER DP 80212650 DP 80643600 DP 31079542 DP 81264600 PP 85351 100 DP 86256600 DP 85351 100 DP 86321200 DP 31191409 DP 86256900 DP 31072942 DP 80308090 DP 82414100 DP 85262953 DP 31128509 DP 74 1 GRI PARTS LIST FOR DP 74 1 GRI DESCRIPTION O RING 30X60X10 KEY PINION GEAR BALL BEARING OIL SIGHT GLASS SCREW 5 16 FILLER PLUG SCREW M10X20 GEAR BOX SELF LOCKING SCREW GEAR O RING 1 78X82 27 GASKET PLUG CENTERING FLANGE BOX 0 P BR S DP 90 1 And DP 90 1 GRI PUMP DIMENSIONS 1274271 22 E
9. ELIEF VALVE RECOMMENDED DISCHARGE Do not operate pump above 145 F 62 C liquid temperature Provide adequate protection by placing guards around the moving parts such as the shaft and pulleys Attach the pump to a strong base plate and anchor it with bolts sufficiently strong to hold it in place Periodically inspect the pump and the system components Perform routine maintenance as required see Maintenance section Wiring an electrically driven pump follow all electrical and safety regulations If the pump is driven by a gasoline engine make sure that the area is well ventilated Checks to make before using the pump With the pump not running check to make sure that the oil level is correct Repeat with the pump running OIL LEVEL USED ON 2 DIAPHRAGM PUMPS LEVEL DURING OPERATION Check to make sure that inlet discharge and by pass hoses have the correct diameter i e never smaller than the union on the pump The hoses should not be crimped and the hose clamps should be sized for hose diameter Prevent any hose restrictions and be sure connections are tight to prevent air entering since these conditions will compromise pump performance If pumping from a tank check to make sure that the control unit by pass line is not too close to the inlet line Make sure that it does not create turbulence inside the tank Check air pressure in the pulsation damper It should be kept within specs given in the
10. J Lod B 2212 j 7 T 22212221 14 47 90 1 OPTIONAL 37 36 41 13 AR A A sie W 40 39 38 46 OPTIONAL 90 1 amp DP 90 1 GRI POS PART NO DESCRIPTION POS PART NO DESCRIPTION QT DP 03004031 PISTON DIAPHRAGM DP 03004000 DESMOPAN PISTON DIAPHRAGM DP 03004036 HPS PISTON DIAPHRAGM DP 03982197 VALVE ASSY DP 03020209 HEAD DP 03002936 VALVE SEAL DP 80321800 O RING 3 0X22 DP 31151509 OUTLET FLANGE 1 2 DP 31151761 FLANGE DP 03000309 SUCTION COVER DP 86213100 SCREW M6X18 DP 80321066 O RING DP 80320830 O RING DP 03000109 CRANKCASE DP 86290000 SCREW 8 55 DP 03003361 MOUNTING RAIL DP 80320000 O RING DP 84054200 90 DEG ELBOW CONNECTOR DP 82004900 WING NUT M34 DP 83506210 NIPPLES DP 03001631 VALVE SEAL DP 86273000 SCREW M8X30 DP 84368500 WASHER 23000832 OIL FILLER DP 80318000 O RING DP 85275000 OIL FILLER CAP DP 82412000 GASKET PUMP KIT ORDER DP 03987497 VALVE KIT ORDER DP 03987597 12 DP 81264600 DP 03001161 DP 94004776 DP 03001261 DP 80133100 DP 03000509 DP 03000609 DP 81850250 DP 85200600 DP 80000300 DP 86318500 DP 17001361 DP 80226410 DP 03001561 DP 03001826 DP 81293300 DP 03000801 DP 86289300 DP 03002197 DP 24304097 DP 31148232 DP 84381000 DP 86321200 DP 84358500
11. LT IN SERIOUS INJURY AND OR PROPERTY DAMAGE AND WILL VOICE THE PRODUCT WARRANTY IF INDOUBT ABOUT YOUR APPLICATION CONTACT YOUR STOCKING DEALER OR THE CDS JOHN BLUE TECHNICAL STAFF AT 1 800 253 2583 BE CAREFUL REMEMBER SAFETY IS NO ACCIDENT TO THE OWNER This manual has been prepared and illustrated to assist you in the maintenance of your CDS JOHN BLUE PUMP Enter your serial number and date of purchase in the space provided below for future reference in service information or for ordering parts Because our engineering department is constantly improving products we reserve the right to make design and specification changes without notice Serial No Purchase Date N O1 S S 10 INSTALLATION AND GENERAL SAFETY INFORMATION Always mount pump with oil sight tube in upright position Proper selection of type and size hose is vital to good performance Diameter of inlet hose should be at least that of the pump inlet hose barb or greater Use only hoses rated for maximum pressure rating of the pump Use of a pressure relief device on the discharge side of pump is required to prevent damage from pressure build up if the discharge is closed or blocked while the power source is still running Install one or more suitably sized strainers at least one and a half times flowrate on the pump supply The filtering service should be dimensioned as required INSTALLATION DIAGRAMS OF THE PUMP PRESSURE R
12. TROUBLESHOOTING CHART SEE BACK COVER w DP 74 1 And DP 74 1 GRI PUMP DIMENSIONS 239 9 471 201 7 97 Ur e LES ACZ Lo 1 4 I 29 L R 220 8 6 H aw BROT ATZ B th YI E U 5 H 5 11 0 47 1604 TWNOILdO b 74 1 8 DP 74 1 GRI DP 03004031 DP 03004000 DP 03004036 03982197 03020209 03002936 80321800 31151509 31151761 03000309 86213100 80321066 80320830 03000109 86290000 03001461 80320000 84054200 82004900 83506210 03001631 86273000 84368500 23000832 80318000 85275000 82412000 81264600 DESCRIPTION PISTON DIAPHRAGM DESMOPAN PISTON DIAPHRAGM HPS PISTON DIAPHRAGM VALVE ASSY HEAD VALVE SEAL O RING 3 0X22 OUTLET FLANGE G 1 2 FLANGE SUCTION COVER SCREW 6 18 O RING 2 62X101 27 O RING 2 62X36 14 CRANKCASE SCREW 8 55 MOUNTING RAIL O Ring 2 62 22 22 90 DEG ELBOW CONNECTOR WING NUT M34 NIPPLES G 3 4 M34 VALVE SEAL SCREW M8X30 WASHER DIA 8 4X15X1 5 OIL FILLER O RING 2 62X15 08 OIL FILLER CAP GASKET 45 9 1 5 BALL BEARING DIA 20X52X15 PUMP KIT ORDER DP 03987497 VALVE KIT ORDER DP 03987597 38 39 40 40 41 42 42 43 44 46 47 48 49 61 62 63 PART NO
13. nt damage to the shaft supports and to the crankcase If oil volume increases due to high operating temperature and the oil reaches the level of the plug stop the pump to prevent damage from internal overpressure After Use After use in order to prevent damage flush pump and let operate for a few minutes at working pressure with a solution that will neutralize the liquid last pumped refer to that manufacturer s instructions Afterward empty the pump so that the pressure drops to zero 0 and then let the pump run without liquids for two minutes To protect pump from freezing flush pump per instructions above after use and then flush with straight RV antifreeze Empty the pump per the instructions above Ordinary Maintenance Change oil every 500 hours as follows Remove cap from oil sight tube and drain plug Turn pump upside down and rotate the shaft by hand until oil stops flowing out It is recommended to make an inside washing with gasoline or diesel oil Put the drain plug back and pour oil into sight tube while turning the pump shaft Be sure oil is at the indicated level and care not to exceed it Start the pump at pressure 0 for a few minutes to allow the correct lubrication of inside parts then check oil level Coupling to Agricultural Machinery 1 Check that the PTO of the machine does not exceed the max rpm shown on the pump plate 2 Ifthe PTO is synchronized with the motor speed consult
14. pany makes no warranties in respect to parts accessories or components not manufactured by CDS John Blue Company same ordinarily being warranted separately by their respective manufacturers el DIVISION OF ADVANCED SYSTEMS TECHNOLOGIES HUNTSVILLE AL 256 721 9090 c Ba a 7 2 2 A _ Dr gt NE Eg AE A A s gt gt tm MET
15. the service manual to get gear number and rpm corresponding to the max pump rotation speed 3 When the rpm of the PTO is higher than the max speed use the suggested reduction gear 4 Disconnect the PTO when moving with pump out of service if that is impossible then disengagement should be provided 5 Disconnect the PTO when changing direction Coupling to electric motors and gasoline engines 1 For direct coupling always use the suggested reduction gear 2 For coupling with pulley check alignment of the two pulleys Motor RPM K Pump RPM Maximum Transmission Ratio After determining K you can establish the motor or pump pulley diam Pump Pulley Pitch Diameter _ K Motor Pulley Pitch Diam m p Pump Pulley Pitch Diam p 0 Motor Pulley Pitch g x K MAINTENANCE FOR DIAPHRAGM PUMPS Routine maintenance on the pump includes changing the diaphragms oil valve assembly o rings all of which are normal wear parts 1 Valve assembly and O Rings Replacement Occasionally debris can cause the valves to not seat properly or damage o rings To check for this problem please follow these steps Remove the valve cover consult the exploded drawing of the pump remove the valves check for debris and wear as well as o rings Replace necessary parts and reassemble 8 Repeat for all valves Consult the parts list for the valve kit or o ring kit part numbers gt 2 Diaphraqm Replacement
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