Barnes 2CDG3, 2CDG5, 2ADG3, 2ADG5, 3CDG3 Installation And Operation Manual

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BARNES

INSTALLATION and OPERATION MANUAL

Diaphragm Pumps

Cast Iron (CDG) & Aluminum (ADG)

Models: 2CDG3, 2ADG3

IMPORTANT: Read all instructions in this manual before operating pump.

As a result of Crane Pumps & Systems, Inc., constant product improvement program, product changes may occur. As such Crane Pumps & Systems, Inc., reserves the right to change product without prior written notification.

2CDG5, 2ADG5 3CDG3, 3ADG3 3CDG5, 3ADG5

PUMPS & SYSTEMS

A Crane Co. Company

420 Third Street/P.O. Box 603 83 West Drive, Brampton Piqua, Ohio 45356-0603 Ontario, Canada L6T 2J6 Phone: (937) 778-8947 Phone: (905) 457-6223 Fax: (937) 773-7157 Fax: (905) 457-2650 www.cranepumps.com

Form No. 082923-Rev. B

TABLE OF CONTENTS

WARN INGS AND SAFETY PRECAUTIO NS .................................................................... ... 3

A. PUMP SPECIFI CATIONS ...... ..... .... ..... .... ..... .... ................................................................... 4 - 5

B. GENERAL INFORM ATION .... ..... .... ..... .... ..... .... .... ..... .... ..... ................................................. 6

C. PREPARE PUMP FOR OPERATION ...... ..... .... .... ..... .... ..... .... ..... .... .... ..... .... ....................... 7

D. MAINTENANCE INSTRUCTI ONS ............................................... .... .... ..... .... ..... .... ..... .... ..... 8

E. TROUBLE SHOOTING .... .... ..... .... .................................................................................. ..... 9

F. REPLACEMENT PARTS ............................................................. .... .... ..... .... ..... .... ..... .... ..... 9

EXPLODED VIEW, .... .... ..... .... ..... .... ..... .... ..... .... .... ............................................................... 10

PARTS LIST - SERIES 2CDG & 3CDG ..... ..... .... ..... .... .... ..... .... ..... .... ..... ............................. 11 - 12

PARTS LIST - SERIES 2ADG & ACDG ... ..... .... .... ..... .... ..... .... ..... .... .... ..... .... ..... .................. 13 - 14

RETURNED GOODS POLICY .... .... ..... .... ..... .... .... ..... .... ..... .... ..... ........................................ 15

WARRANTY WARR ANT Y INFORMATION & REGISTRATI ON

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

Other brand and product names are trademarks or registered trademarks of their respective holders. ® Barnes is a registered trademark of Barnes Pumps, Inc. © Barnes Pumps, Inc.1987, 1995, 2002 Alteration Rights Reserved. Printed i n U.S.A.

WARNING

SAFETY FIRST!

PLEASE READ THIS BEFORE INSTALLING

OR OPERATING PUMP.

GENERAL

1. Most accidents can be avoided by using COMMON SENSE.

2. Read the operation and maintenance instruction manual supplied with the pump.

3. Do not wear loose clothing that may become entangled in the impeller or other moving parts.

4. Always wear appropriate safety gear, such as safety glasses, when working on the pump or piping.

5. Bronze/brass and bronze/brass fitted pumps may contain lead levels higher than considered safe for potable water systems. Various government agencies have determined that leaded copper alloys should not be used in potable water applications. For non-leaded copper alloy materials of construction, please contact factory.

PUMPS

6. Pumps build up heat and pressure during operation-allow time for pumps to cool before handling or servicing.

7. Only qualified personnel should install, operate and repair pump.

8. Keep clear of suction and discharge openings. DO NOT insert fingers in pump with power connected.

9. Do not pump hazardous materials (flammable, caustic, etc.) unless the pump is specifically designed and designated to handle them.

10. Do not block or restrict discharge hose, as discharge hose may whip under pressure.

11. Make sure lifting handles are securely fastened each time before lifting.

12. Do not lift pump by the power cord (if applicable).

13. Do not exceed manufacturers recommendation for maximum performance, as this could cause the motor to overheat.

14. Secure the pump in its operating position so it can not tip over, fall or slide.

15. Keep hands and feet away from impeller when power is connected.

16. Submersible Pumps are not approved for use in swimming pools, recreational water installations, decorative fountains or any installation where human contact with the pumped fluid is common.

17. Do not operate pump without guards and safety devices in place.

18. When towing pump behind a vehicle; make sure hitch is properly attached, always attach safety chains.

19. Always replace safety devices that have been removed during service or repair.

20. Operation against a closed discharge valve will cause premature bearing and seal failure on any pump, and on end suction and self priming pump the heat build may cause the generation of steam with resulting dangerous pressures. It is recommended that a high case temperature switch or pressure relief valve be installed on the pump body.

ELECTRICAL

21. To reduce risk of electrical shock, pump must be properly grounded in accordance with the National Electric Code (NEC), or Canadian Electrical Code (CEC) and all applicable state, province and local codes and ordinances.

22. To reduce risk of electrical shock, always disconnect the pump from the power source before handling or servicing.

23. Any wiring of pumps should be performed by a qualified electrician.

24. Never operate a pump with a power cord that has frayed or brittle insulation.

25. Cable should be protected at all times to avoid punctures, cut, bruises and abrasions - inspect frequently.

26. Never handle connected power cords with wet hands.

27. Never operate a pump with a plug-in type power cord without a ground fault circuit interrupter.

28. Do not remove cord and strain relief. Do not connect conduit to pump.

29. To reduce risk of electrical shock, all wiring and junction connections should be made per the NEC or CEC and applicable state or province and local codes. Requirements may vary depending on usage and location. See wiring diagrams in manual.

GAS/DIESEL ENGINE POWER PUMPS & DRIVES ONLY

30. Never operate in an enclosed building or area where exhaust gases can accumulate.

31. Do not breath exhaust fumes when working in the area of the engine. (Exhaust gases are odorless and deadly poison.)

32. Never operate near a building where exhaust gases can seep inside.

33. Never operate in a pit or sump without making provisions for adequate ventilation.

34. Allow exhaust system to cool before touching.

35. Never add fuel to the tank while the engine is running. Stop engine and allow to cool.

36. Do not smoke while refueling the engine.

37. Do not refuel near open flame.

38. Carefully read instruction manuals supplied by engine manufacturer before attempting to assemble, operate or service the engine or any part. The "WARNING" statements indicate potentially hazardous conditions for operator or equipment.

IMPORTANT! Barnes® Pumps, Inc. is not responsible for losses, injury, or death resulting from a failure to observe these

safety precautions, misuse or abuse of pumps or equipment.

SECTION: A- PUMP SPECIFICATIONS: SKID MOUNTED

SUCTION/DISCHARGE:

2CDG, 2ADG: 2" x 2" NPT- Faced Nipples 3CDG, 3ADG: 3" x 3" NPT- Faced Nipples

LIQUID TEMPERATURE: 160° F Continuous. SOLIDS: 2" 1.5" Spherical

3" 1.75" Spherical

SUCTION CHAMBER:

ADG: Aluminum, Class 319. CDG: Cast Iron ASTM A-48, Class 30.

DISCHARGE CHAMBER:

ADG: Aluminum, Class 319. CDG: Cast Iron ASTM A-48, Class 30.

WATER BOX: ADG: Aluminum, Class 319.

CDG: Cast Iron ASTM A-48, Class 30.

DIAPHRAGM BOTTOM:

ADG: Aluminum, Class 319. CDG: Cast Iron ASTM A-48, Class 30.

DIAPHRAGM: Natural Rubber GASKETS: Velumoide CRANK ARM: Steel CF1018 CONNECTING ROD: Al Tenzalloy CONN. ROD BEARING: Cam Roller FRAME: Aluminum, Class 319. GEAR SHAFT: Steel 4142. OUTPUT GEAR: Ductile #80-60-03 INTERMEDIATE GEAR: Ductile #80-60-03 GEAR CASE: Aluminum, Class 319.

GEAR COVER: Aluminum, Class 319. BEARINGS: Ball FLAP VALVE: Natural Rubber PINIONS: Steel, HC C1144 Hardened VALVE WEIGHTS: Steel-Iridite Plated PAINT: Air Dry Enamel. TRANSMISSION: Enclosed, Oil Bath, Double Reduction. GEAR RATIO: 43:1 OUTPUT STROKES: 60 per minute, (Note: Strokes may be

adjusted between approx. 50 and 65 strokes per minute.

ENGINES: Make/Model: Briggs & Stratton, 8 - CDG3, ADG3

Briggs & Stratton, 13 - CDG5, ADG5

Type: 4 Cycle, Single Cylinder, Air Cooled. Dispacement: 7.75 Cu. In. (B&S 8)

12.57 Cu. In. (B&S 13)

Fuel Capacity: 2 Quarts (B&S 8)

4 Quarts (B&S 13)

Air Cleaner: Dual Element Oil Capacity: 1.25 Pints (B&S 8)

1.25 Pints (B&S 13) w/Low Oil Pressure Shut Down.

Start Method: Recoil Rope Rating: 3.5HP @ 3600RPM (B&S 8)

5.0HP @ 3600RPM (B&S 13)

G Dia.

MODEL A B C D E1 E2 GJKL PR

2" 37.12

(943mm)

4.93

(125mm)

24.87

(632mm)

16.25

(413mm)

5.12

(130mm)

5.12

(130mm)

0.43

(11mm)

22.62

(575mm)

4 Holes

6.12

(156mm)

(138mm)

5.43

24.75

(629mm)

12.37

(314mm)

SECTION: A- PUMP SPECIFICATIONS: WHEEL MOUNTED

SUCTION/DISCHARGE:

2CDG, 2ADG: 2" x 2" NPT- Faced Nipples 3CDG, 3ADG: 3" x 3" NPT- Faced Nipples

LIQUID TEMPERATURE: 160° F Continuous. SOLIDS: 2" 1.5" Spherical

3" 1.75" Spherical

SUCTION CHAMBER:

ADG: Aluminum, Class 319. CDG: Cast Iron ASTM A-48, Class 30.

DISCHARGE CHAMBER:

ADG: Aluminum, Class 319. CDG: Cast Iron ASTM A-48, Class 30.

WATER BOX: ADG: Aluminum, Class 319.

CDG: Cast Iron ASTM A-48, Class 30.

DIAPHRAGM BOTTOM:

ADG: Aluminum, Class 319. CDG: Cast Iron ASTM A-48, Class 30.

DIAPHRAGM: Natural Rubber GASKETS: Velumoide CRANK ARM: Steel CF1018 CONNECTING ROD: Al Tenzalloy CONN. ROD BEARING: Cam Roller FRAME: Aluminum, Class 319. GEAR SHAFT: Steel 4142 OUTPUT GEAR: Ductile #80-60-03 INTERMEDIATE GEAR: Ductile #80-60-03 GEAR CASE: Aluminum, Class 319. GEAR COVER: Aluminum, Class 319.

BEARINGS: Ball FLAP VALVE: Natural Rubber PINIONS: Steel, HC C1144 Hardened VALVE WEIGHTS: Steel-Iridite Plated PAINT: Air Dry Enamel. TRANSMISSION: Enclosed, Oil Bath, Double Reduction. GEAR RATIO: 43:1 OUTPUT STROKES: 60 per minute, (Note: Strokes may be

adjusted between approx. 50 and 65 strokes per minute.

TIRES: 8" x 1.75 (Use On CDG3-1, CDG5-1,

ADG3-1 & ADG5-1)

ENGINES: Make/Model: Briggs & Stratton, 8 - CDG3, ADG3

Briggs & Stratton, 13 - CDG5, ADG5

Type: 4 Cycle, Single Cylinder, Air Cooled. Dispacement: 7.75 Cu. In. (B&S 8)

12.57 Cu. In. (B&S 13)

Fuel Capacity: 2 Quarts (B&S 8)

4 Quarts (B&S 13)

Air Cleaner: Dual Element. Oil Capacity: 1.25 Pints (B&S 8)

1.25 Pints (B&S 13) w/Low Oil Pressure Shut Down.

Start Method: Recoil Rope Rating: 3.5HP @ 3600RPM (B&S 8)

5.0HP @ 3600RPM (B&S 13)

MODEL A E J K L P

2" 39.87

(1013mm)

12.37

(314mm)

22.50

(572mm)

4.93

(125mm)

4.25

(108mm)

24.75

(629mm)

SECT ION B: GENERAL INFORMATION

B-1) To the Purchaser:

Congratulations! You are the owner of one of the finest pumps on the market today. Barnes® Pumps are products engineered and manufactured of high quality components. Over one hundred years of pump building experience along with a continuing quality assurance program combine to produce a pump which will stand up to the toughest applications.

This Barnes Pumps, Inc. manual will provide helpful information concerning installation, maintenance, and proper service guidelines.

B-2) Rec eiving

Upon receiving the pump, it should be inspected for damage or shortages. If damage has occurred, file a claim immediately with the company that delivered the pump. If the manual is removed from the packaging, do not lose or misplace.

B-3) Storage:

Short Term- Barnes Pumps are manufactured for efficient performance following long inoperative periods

in storage. For best results, pumps can be retained in storage, as factory assembled, in a dry atmosphere with constant temperatures for up to six (6) months.

Long Term- Any length of time exceeding six (6) months, but not more than twenty four (24) months. The units should be stored in a temperature controlled area, a roofed over walled enclosure that provides protection from the elements (rain, snow, wind blown dust, etc..), and whose temperature can be maintained between +40 deg. F and +120 deg. F. If extended high humidity is expected to be a problem, all exposed parts should be inspected before storage and all surfaces that have the paint scratched, damaged, or worn should be recoated with a water base, air dry enamel paint. All surfaces should then be sprayed with a rust-inhibiting oil.

B-4) SERVICE CENTERS:

For the location of the nearest Barnes Pumps Service Center, check your catalog, your Barnes Pumps, Inc. representative or Barnes Pumps, Inc. Service Department in Piqua, Ohio, telephone (937) 778-8947.

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