Great Plains CDS User Manual

NGP SERIES PISTON METERING PUMP

PARTS AND

INSTRUCTION MANUAL

NGP-6055 Shown

CDS-JOHN BLUE COMPANY

DIVISION OF ADVANCED SYSTEMS TECHNOLOGY, INC.

290 Pinehurst Drive - Huntsville, Alabama 35806

P.O. Box 1607 - Huntsville, Alabama 35807

Telephone: (256) 721-9090 - FAX: (256) 721-9091 - Toll Free: 1-800-253-2583

Printed in U.S.A. 12-M-43 Rev 08/13

SAFETY PRECAUTIONS

 Equipment should be operated only by responsible people.  A careful operator is the best insurance against an accident.  Fill system with WATER first and check output.  Check all valves, fittings, hose clamps, etc. for wear / leaks before admitting process fluid to the 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 APPLICATIONS 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 RESULT IN SERIOUS INJURY AND/OR PROPERTY DAMAGE AND WILL VOID THE PRODUCT WARRANTY. IF IN DOUBT ABOUT YOUR APPLICATION, CONTACT YOUR STOCKING DEALER OR THE CDS-JOHN BLUE TECHNICAL STAFF AT 1-800-253-2583.

Important Message to Owners / Operators of Pumps

Equipped with Lever Actuated Throw Out Clutches

When using a pump operated by a lever actuated throw out clutch, the rope must be routed by use of eyelet pulleys such that the rope cannot become entangled with or come in contact with any moving parts of the tractor or the applicator such as PTO shafts, tractor tires, ground drive units, etc. If eyelet pulleys are not found packed in with the pump, please contact your selling agent or CDS – John Blue Company (1-800-253-2583) immediately before any operations are undertaken.

Verification must be made prior to any operation that the rope is clear of any moving parts while not only driving straight but when making turns either right or left. Verification must be made prior to any operation that the properly routed rope contains no loops, which might become entangled with any part of the equipment or operator.

At no time should the rope be attached to any clothing worn by or to any body parts of the operator such as hands, arms, legs, etc.

We fully understand these are normal precautions owners / operators should take prior to and while operating equipment. However, we wish to remind you that failure to comply with all safety regulations regarding instructing operators in the use of moving equipment and actual operation of the equipment may lead to serious injury and possible death.

This manual has been prepared and illustrated to assist you in the maintenance of your CDS – JOHN BLUE PUMP. Enter your serial number and the date of the 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.

Model Number: ________________ Serial Number: ________________ Purchase Date: ____ ____________

To The Owner

TABLE OF CONTENTS

Safety Precautions …………………………………………………………………………………… …………… 2 Note to the Owner ………………………………………………………………………………… ………………. 2 Table of Contents …………………………………………………………………………………………….……. 3 Pump Specifications …………………………………………………………………………………… ….……… 3 Introduction ………………………………………………………………………………………………….……… 4 Installation …………………………………………………………………………………………………..……… 5

Pump Setting ……………………………………………………..………………………………………….....…. 6

Initial Start-Up of Pump ……………………………………………….…………………………………….……. 8

Pump Calibration …………………………………………………….………………………………………….... 8

Pump Accuracy ………………………………………………………………………………………… …………. 8 Maintenance ……………………………………………………………………………..……………………..….. 9 Storage …………………………………………………………………………..…………………………………. 9 Service Maintenance ………………………………………………………………..………………… ………..… 10 Crankcase Disassembly ………………………………………………………… ………….………………..…… 12 Parts List NGP-6050 & NGP-7050 [Single Piston] ………………………………………………………….…. 14 Parts List NGP-8050 & NGP-9050 [Double Piston] ……………………………………………..…………….. 16 Parts List for Double Adjustable Double Piston ………………...………………………………..…………….. 18 Parts List Optional Clutch ……………………………………………………………………………………...…. 19 Dimensional Footprints …………………………………………………………… …………………….………… 22

Trouble Shooting …………………………………………………………………………………………....…….. 23

Warranty ……………………………………………………………………………………………………....……. 24

PUMP SPECIFICATIONS

Universal Specifications

Operating Pressure: MAX 120 PSI Operating Speed: MAX 450 RPM Rotation: Clockwise or Counter-clockwise Drive: No. 50 Roller Chain Crankcase Lubrication: SAE 90 Gear Oil Grease Zerks: Multipurpose Grease

Model Specifications

Pump Series: NGP-4055 NGP-5055 NGP-6050 NGP-7050 NGP-8050 NGP-9050 Output Volume 10.2 20.4 21.0 34.2 42.0 68.4 Max Gal/Min Output Disp. .023 .046 .047 .076 .093 .152 Max Gal/Rev Required H.P. __ __ 2.25 3.00 4.50 6.00 Theoretical Physical Dims. 10x16x9 14x16x9 10x15x9 10x19x11 14x15x11 14x19x13 W x L x H (in.) Weight __ __ 65 105 125 155 Lbs. Crankcase Oil Cap. 0.5 2.5 0.5 1.5 2.5 5.4 Pints Inlet/Outlet Ports 1” 1” 1-1/2” 1-1/2” 1-1/2” 1-1/2” Female Pipe Thd Optional Flanges 200 200 220 220 220 220 Flange Size

INTRODUCTION

The NGP series pump is a positive displacement variable stroke metering pump. It is specifically designed to accurately meter liquid fertilizer solutions. The pump’s construction is of rigid thick walled cast iron cylinders and manifolds for durability and long life. The check valves, piston, and rod are constructed of stainless steel for improved corrosion resistance. Optionally, the pump may be purchased with stainless cylinders and manifolds.

The NGP series pump functions as a positive displacement metering device which operates in direct relati on to the ground speed through a ground drive system (model number DRV-3xxx). The application rate can be set (covered under the “Pump Setting” section) before application begins and the GPA (gallons per acre ) application will be accurate regardless of the varying speeds of the drive mechanism.

The NGP series pump may also be used with one of our hydraulic drive kits (model number VRH-xxx-xx) to provide variable rate application when used with one of many different control systems. The pump provides several advantages over other types of pumps such as: suction capability from saddle tanks, stable settings that do not vary with temperature, and proven durability and longevity.

The NGP series pump is designed to control the overall gallons of solution metered over an acre, independent of downstream discharge pressure (120 psi max). The only function of the flow divider or row orifices in a CDS – John Blue pump system is to divide liquid accurately row to row - not to meter the overall application rate.

Optional 220 size Flanges Shown

Rod Packing

Piston

Discharge Valves Top Position (Stiff Spring, Flat Side In)

Not Visible

Piston Packing

Discharge Port 1-1/2” NPT

Suction Valves Bottom Position (Weak Spring, Flat Side Out)

Suction Port 1-1/2” NPT

Sprocket

Valve Access Cover

Oil Fill Plug Vent Plug

Oil Level Plug

Rear - Not Shown

Oil Drain Plug

Rear - Not Shown

Pump Setting Hub & Pointer

Packing Grease Zerk

INSTALLATION

MOUNTING

 The NGP pump should be mounted on a rigid base in a horizontal position.  The mount position should allow for a straight drive chain and proper tightness.  Chain idlers should be installed on the slack side of the drive chain.  The supplied rubber washers are installed between the pump and mount.  Caution should be exercised on implements with wings or folding members to assure that sufficient area is

allowed around the pump and plumbing to not cause contact or binding.

 Verify that the rear tractor wheel will clear the pump during sharp turns.  The oil vent plug should be installed in the oil fill located on top of crankcase.

SUCTION PLUMBING

 An adequately sized 30 mesh strainer should be installed on the suction side of

the pump and should be checked at each tank filling for debris, which could cause suction restriction, starving the pump of flow.

 The NGP pump does produce suction to pull fluid from the tank; however, it is

recommended to mount the pump level or below the tank, if possible, to assure the most effective and quickest prime.

 Install the process fluid suction line as straight as possible avoiding restrictions from kinks or e x tremely

sharp turns. This will ensure even flow during maximum pump output.

 Quick connect fittings should be checked and double checked to verify that no leakage is present. Quick

connects, although commonly necessary, quite often can produce a suction leak if installed in a bind allowing air to enter the pump, causing loss of prime and / or reduction in pump output.

 It is recommended that suction line hoses be double clamped. Again, this is an area that can produce a

suction air leak into the pump, even if no drip from the hose is present.

DISCHARGE PLUMBING  It is not recommended to install a discharge strainer as these could clog with debris causin g significant

discharge pressure and possible system damage in positive displacement pump applications.

 Flow dividers may be installed either directly on top of the discharge port or remote mounted.  Orifice applications must pay particular attention for proper orifice sizing for the specified application rate.  It is recommend that applications using a double piston pump with two flow dividers remove the common

manifold and plumb each flow divider independently to each piston to assure accuracy.

 On – The – Go Variable Rate applications require that a CDS – John Blue Co. flow divider distribution

manifold be used that will automatically and accurately adjust for varying on the go rate changes.

WARNING: The flow range of a NGP pump far exceeds the flow curve of a single orifice operating below 120 psi. For Example: An orifice application at 30 psi discharge pressure for a rate of 20 GPA @ 4 mph will produce 422 psi when the rate is adjusted to 50 GPA and ground speed increased to 6 mph.

PUMP SETTING

The NGP pump output is determined by the drive sprocket ratio and the stroke setting. There are two ways to find the proper setting for your pump:

1. Using the online flow rate calculator at www.cds-johnblue.com .The icon is on the

right-hand side of the page, and there is a mobile version available here:

2. Using the slide chart (115698-91) supplied with the pump – follow the example below:

MAXIMUM GROUND SPEED

SPROCKET RATIO

LOADED RADIUS

STANDARD SPROCKET COMBINATIONS

SPROCKET RATIO

Standard Sprocket Combinations Standard sprocket combinations may be used for equipment with only one chain from the ground or press wheel sprocket to the pump sprocket. For example: an applicator with a 60 tooth drive sprocket on the tire driving a 16 tooth driven sprocket on the pump can use the 16 to 60 mark on the slide chart.

Non-Standard Sprocket Combinations If you are using sprocket combinations with multiple sprockets, such as with a jack shaft, use the following formula to determine sprocket ratio:

For example: an applicator with a 50 tooth on the drive wheel, driving to a 24 tooth on the jack shaft, then a 36 tooth on the jack shaft driving up to a 16 tooth pump driven sprocket, would yield a 4.69 drive ratio.

Set the sprocket ratio on the slide chart using the 4.69 calculation for the example above.

SWATH WIDTH

Drive Sprocket Driven Sprocket

50 T (@ Drive Wheel) 36 T (@ Drive Shaft) 50 36 24 T (@ Driven Shaft) 16 T (@ Driven Pump) 24 16

X X

PUMP SETTING

= Sprocket Ratio

= 4.69 Sprocket Ratio

GALLONS PER ACRE

LOADED RADIUS

The measurement for the loaded radius must be from the Manufacturer of the tire or be measured under loaded conditions. The loaded radius tire is always the tire that has the first drive sprocket attached to its hub.

Ground Wheel Drive Arrangement Measure the loaded radius from the center of the hub to the bottom of the tire where it rests on the ground.

Press Wheel Drive Arrangement Measure the loaded radius from the center of the press wheel shaft to where the wheel rests against the tire. The press wheel must be engaged for normal operation to give an accurate reading.

SWATH WIDTH

To determine the swath width, count the number of outlets and multiply by the distance (inches) between any two outlets, nozzles, or shanks. This assumes that all outlets are equally spaced, if outlets are not evenly spaced, figure the entire length of the boom or toolbar from end nozzle to end nozzle and allow for coverage beyond the ends. For example, an 11 row boom at 30” would have a swath width of 330”

SETTING THE PUMP

Read the desired pump setting from the bottom scale on the pump setting chart. Loosen the setting pointer nut and rotate the setting hub until the setting pointer is over the desired setting. The setting wrench will facilitate rotation of the setting hub. Once proper pump setting is achieved, tighten the setting pointer nut.

EXAMPLE:

An applicator is equipped with a NGP-6050 series pump, 11L x 15” tires, a 60 tooth drive sprocket, and a 16 tooth pump driven sprocket. It is desired to apply 33 gallons per acre on a 360” swath. The following steps will determine correct pump setting:

SET SWATH WIDTH AT DIAMOND

SET LOADED RADIUS

1 2

AT SPROCKET RATIO

1. Set loaded radius of tire (13.5”) under the sprocket combination of 16 to 60 in the top window.

2. Set the swath width (360”) under the diamond in the middle

window.

3. Read that the pump setting is approx. 9 at 33 gallons per

acre on the NGP-6055 scale in the bottom window.

4. Set the pump to setting 9 to achieve 33 gallons per acre

Note: The max. ground speed is read above the diamond as

READ PUMP

approx. 9 mph to avoid exceeding 450 pump rpm.

SETTING

INITIAL PUMP START UP

Verify that all installation guidelines have been followed as outlined in the installation section of this manual.

 Fill the tank full of water to test for leaks in the plumbing system and output of the pump.  Fully open the valve at the tank allowing water to fill the suction line and check for leaks.  Set the pump to pump setting 10.  Before installing nozzles or orifices (if used), prime the pump and purge the system of air and foreign

material by slowly pulling the applicator 100 to 200 yards.

 Turn off the valve at the tank, open strainer, check for foreign material and clean the screens.  The CDS – John Blue flow divider is automatic and requires no calibration; however, if nozzles or orifices

are used, verify that the orifices are sized properly as to not produce high discharge pressure.

 Pull the machine over known acreage and verify the application accuracy with water prior to field

application of chemical. Note that tank level marks can give false readings if read on uneven ground.

PUMP CALIBRATION

The NGP pump is calibrated from the factory; however, if the setting scale, hub, or pointer is replaced, use the following procedure to calibrate the pump output with scale readings.

 Remove the valve cover and outboard cylinder (see maintenance section).  Set the pump on pump setting 5 for all pump sizes.  Rotate the crankshaft until the piston is as far in as it will go. Measure the distance from the end of the

piston to the inboard cylinder flange. Rotate the crankshaft until the piston is as far out as it will go and measure again to the same place. The difference in length is the stroke length, which at pump setting 5 should be 9/16” for the NGP-4050, 5050, 6050, & 8050, or 15/16” for the NGP-7050 & 9050.

 If the distance is less than the required amount, reset the pointer at a higher setting, if it is greater; reset

the pointer at a lower setting. Repeat this procedure to obtain the required measurement.

 Once accomplished, loosen the setting scale screws until the 5 is directly under the pointer and secure the

scale in position with the three scale screws.

 Replace the outboard cylinder and valve cover, making sure that the valves are in their proper orientation

as covered under the maintenance section.

PUMP ACCURACY

A catch test may be performed to verify accuracy (not as a calibration method) by priming the pump and catching all of the pumped fluid from the discharge for a known number of revolutions. See chart below:

Pump Series Pump Setting # of Revolutions Total Pump Output NGP-4050 8-1/4 10 1-1/2 Pints NGP-5050 8-1/4 10 3 Pints NGP-6050 8 10 3 Pints NGP-7050 8-1/4 10 5 Pints NGP-8050 8 10 6 Pints NGP-9050 8-1/4 10 10 Pints

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