Centrifugal PTO Pumps 2 nd Edition MAN072 November 2005 2005
Centrifugal PTO pumps are manufactured by AMADAS Industries. You can find us on the Web at: www.amadas.com or e-mail us at: amadas@amadas.com You can also contact us at: P.O. Box 1833 / Suffolk, VA 23439 (mailing) 1100 Holland Road / Suffolk, VA 23434 (shipping) (757) 539-0231 (phone) (757) 934-3264 (FAX) P.O. Box 3687 / Albany, GA 31701 (mailing) 1701 South Slappey Blvd. / Albany, GA 31706 (shipping) (229) 439-2217 (phone) (229) 439-9343 (FAX)
PTO Pump Introduction Table of Contents Welcome... ii 1. Safety... 1 Overview... 2 Safety Symbols... 3 Safety Guidelines... 5 Safety Decals... 6 2. Set Up... 7 Before Setting Up... 8 Setup Instructions... 9 3. Operation... 11 Pre-Operation Checklist... 12 How to Use the PTO Pump... 13 How to Stop the PTO Pump... 14 4. Maintenance... 15 Regular Maintenance... 16 Before Performing Maintenance... 16 Maintenance Schedule... 17 Gearbox... 18 Primary Valve... 18 Priming Pump... 18 PTO Drive Shaft... 18 Packing Gland... 19 Winterizing... 19 Pump Body... 19 Water-Cooled Gearboxes... 19 PTO Drive Shaft... 20 Gearbox... 20 General Winterizing... 20 Troubleshooting... 21 Appendix... A 1 PTO Drive Shaft Alignment... A - 2 Warranty Statement MAN072 09/08/09 i
Introduction PTO Pump Welcome to AMADAS Industries With origins dating back to 1963, AMADAS Industries and its predecessors have a long history of providing high quality, reliable, innovative equipment for the farming industry. AMADAS equipment is currently at work throughout the United States and in many other countries. This equipment includes machinery such as the Magnum Fource Peanut Combine, Reel Rain Traveler Irrigation System, Tree Bark Processing and Packaging Machinery, the Soils and Bark Bagger, and centrifugal PTO pumps. ii 09/08/09 MAN072
PTO Pump Introduction PTO Pumps Congratulations on your purchase of an AMADAS PTO pump. AMADAS centrifugal PTO pumps are available to suit most types of irrigation systems. These proven, rugged, efficient pumps are cart-mounted and easily transportable. AMADAS PTO pumps are designed for long life as well as efficiency. We are confident you will receive many years of dependable service from your PTO pump. Standard Features Each of our PTO pumps includes the following standard features: PTO drive shafts Primer with valve Pressure gauge Suction adapter Heavy duty pump cart with semipneumatic tires. Optional Features The following optional features are available for the chain conveyor: Suction line assembly with flexible hose pump connection Foot-valve Strainer. MAN072 09/08/09 iii
Introduction PTO Pump Specifications The following chart lists the specifications of the available PTO Pumps. PTO Pump Performance Model GPM 50 60 70 80 90 100 150 200 250 300 350 400 450 500 600 700 800 1000 1200 1400 Discharge NPT(F) Suction NPT(F) D02/40 PSI 103 103 102 100 99 98 88 71 2" 2" HP 7 8 9 10 10 11 13 15 D3/65 PSI 161 160 156 154 151 146 142 136 4" 4" HP 29 34 38 42 46 50 53 55 DMR 80-3/2* PSI 192 191 190 187 185 182 178 169 157 140 4" 5" HP 50 53 56 60 63 66 70 76 83 90 DMR 83-3/2* PSI 235 235 235 235 235 232 231 224 213 200 4" 5" 61 66 70 75 80 84 88 97 106 114 540 RPM 1000RPM GPM: 50 60 70 80 90 100 150 200 250 300 350 400 450 500 600 700 800 1000 1200 1400 Above details apply to fully fitted pumps iv 09/08/09 MAN072
PTO Pump Safety 1. Safety Overview... 2 Safety Symbols... 3 Safety Guidelines... 5 Safety Decals... 6 MAN072 09/08/09 1
Safety PTO Pump Overview Safety is everyone's responsibility! Although safety features are incorporated into the machine and dangerous areas are marked, ultimately, careful operation is the best way to prevent an accident. To reduce the risk of accidents, please read thoroughly and follow the safety instructions and messages included in this manual and on the machine. Safety Symbols Used Three safety symbols are used on the machine and in this manual. DANGER WARNING CAUTION CAUTION NEVER remove, tamper with, or modify guards or shields! NEVER open or take off the shields while the machine is operating! NEVER run the machine if the shields are missing or removed! Please familiarize yourself with each symbol and its meaning. It is crucial to your safety, and the safety of others, that you follow the safety precautions indicated by these symbols. The section beginning on the next page explains each of these symbols in detail. Protective Devices Protective guards and shields have been installed to protect you from hazards. 2 09/08/09 MAN072
PTO Pump Safety Safety Symbols Danger This symbol indicates an imminently hazardous situation, which if not avoided, will result in death or serious injury. The use of the word DANGER is limited to the most extreme situations. Extreme care should be taken when you near these areas. DANGER decals are located at or as near as possible to these areas. DANGER Warning This symbol identifies areas or practices, which if not avoided, could result in serious personal injury. These injuries could range from minor cuts to dismemberment. Warning decals are located at or as near as possible to these areas. WARNING Caution This symbol identifies a potentially hazardous situation, which if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices that could cause damage to the machine. Caution decals are located at or as near as possible to these areas. CAUTION MAN072 09/08/09 3
Safety PTO Pump Safety Alert Symbol This symbol alerts you to possible hazards. Follow the recommended precautions and safe operating procedures. If you have any questions, please contact your dealer or the manufacturer. Safety Instructions Safety features have been designed into the machine with hazardous areas marked. Please read and follow the instructions in this manual prior to operating, maintaining, or servicing this machine. Notes Throughout the manual, information that needs to be emphasized is set apart with either a "NOTE!" or "IMPORTANT!" heading. Please be sure to read carefully this information, as it usually indicates a situation that could cause machine damage. NOTE! We recommend that you use a flexible hose to connect the discharge pipe to the pump. A flexible hose will eliminate any possible stress on the plump flange. 4 09/08/09 MAN072
PTO Pump Safety Safety Guidelines Do NOT operate the pump above the recommended speeds. The maximum input speed, 640 or 1000 RPM, is specified for each pump. BEFORE servicing the pump: Disengage power to the PTO drive shaft, turn off the tractor, and wait for all moving parts to stop. Disconnect and remove the PTO drive shaft. Many accidents can be prevented by your knowledge of safety. Prevent injuries by reading and following the safety warnings in this manual and on the machinery. Alert others to potential hazards. Wait until pressure drops to 0 (zero) before disconnecting any lines. Remember all machinery can be dangerous if used incorrectly. Please operate carefully. Safety is only a word until it is put into practice! When operating the pump: Keep hands, feet, and clothing away from moving parts. Keep all safety shields in place Verify that everyone is clear of the pump and tractor, both prior to starting and during operation. Do NOT tow the pump cart at speeds greater than 10 MPH. Do NOT allow anyone to ride on the pump cart. MAN072 09/08/09 5
Safety PTO Pump Safety Decals Safety decals identify specific hazards and general safety. Please note the following about the decals: Keep them clean and legible. Never remove a safety decal from the machine. When you replace a part with a safety decal, also replace that decal. For replacement decals, call your AMADAS parts representative. Replacement safety decals are available free of charge. Decals The following decals are included on the PTO pump. NOTE! AMADAS provides each machine with a basic set of safety decals. These decals are listed on this page. In addition, your machine may include other safety decals as appropriate. 8190 8188 8191 6 09/08/09 MAN072
PTO Pumps Setup 2. Setup Before Setting Up... 8 Setup Instructions... 9 MAN072 09/08/09 7
Setup PTO Pumps Before Setting Up Before you set up your PTO pump, please read the following: Carefully read over the setup instructions and familiarize yourself with the setup procedure. When you connect your pump and tractor for the first time, or change to another tractor, check the length of the PTO drive shaft. If the shaft is too long, you will need to shorten it. Perform the pre-setup inspection indicated on the checklist. Inspection Checklist Remove all packing materials. Carefully inspect your pump and all associated parts and equipment. If there is any evidence of damage from shipment or handling, report it immediately to your AMADAS representative. 8 09/08/09 MAN072
PTO Pumps Setup Setup Instructions 1. Hitch the pump cart to the tractor. 2. Tow the pump to the desired location. Do NOT exceed 10 MPH. 3. Position the pump on level ground as close as possible to the water source. 4. Lubricate the PTO drive shaft universal joints and telescoping tubes. NOTE! We recommend that you use a flexible hose to connect the discharge pipe to the pump. A flexible hose will eliminate any possible stress on the pump flange. 9. Connect the Engine Protection Unit (EPU), if equipped with one. 5. Check the gearbox oil level. Refill with 90W oil if necessary. 6. Install the PTO drive shaft as follows: a. If the PTO drive shaft needs to be shortened, shorten the shaft assembly by cutting equal amounts from both halves. Maintain the maximum possible overlap. b. Keep the PTO drive shaft as straight as possible to minimize universal joint wear and power loss. c. Do NOT operate the shaft at angles exceeding 15 degrees. d. For maximum efficiency, the input and output shafts should be parallel to each other. If necessary, the tractor can be maneuvered until the shafts line up. 7. Submerge the foot-valve or strainer to sit directly on the bed of the water source. A slide or float should be used to prevent mud, sand, or other abrasive materials from entering the pump. 8. Connect the discharge plumbing to the pump. Support any long lengths of pipe that will cause unnecessary stresses on the pipe flange. MAN072 09/08/09 9
Setup PTO Pumps NOTES 10 09/08/09 MAN072
PTO Pumps Operation 3. Operation Pre-Operation Checklist... 12 How to Use the Pump... 13 How to Stop the PTO Pump... 14 MAN072 09/08/09 11
Operation PTO Pumps Pre-Operation Checklist Before using your pump, perform the checklist to make sure that the machine is ready to be used. DANGER Do NOT operate this machine without reading and fully understanding this operator s manual. Failure to do so could result in injury or death to the operator or damage to the pump and/or tractor. Checklist Check that the tractor and pump are correctly positioned. Make sure the PTO drive shaft is as straight as possible. Make sure the input and output shafts are parallel to each other. Check that all safety shields, both on the pump and PTO shaft, are in place. Do NOT operate the pump unless all safety shields are in place! Check that all necessary lubrication has been completed. Verify that all suction and discharge plumping is securely connected. Check the tractor fuel, oil, and water levels. Refill if necessary. Verify that the Engine Protection Unit (EPU), if equipped, is connected. Check that the distribution system is ready for operation. 12 09/08/09 MAN072
PTO Pumps Operation How to Use the Pump IMPORTANT! Since a tractor may be left unattended for an extended period of time during irrigation work, we recommend you use an Engine Protection Unit (EPU). An EPU will automatically shut down the tractor in the event of a problem such as loss of engine oil pressure, engine overheating, excessive pump pressure, or the loss of pump prime. discharge water after a second attempt, stop the tractor immediately and examine the pump for possible problems. CAUTION Do NOT prime the pump connected to the pressure side while the PTO shaft is driving the pump. Disengage the power to the PTO shaft before priming the pump. 1. Close the priming pump drain cock. 2. If the primer pump is mounted on the pressure side, open the isolating valve. 3. Prime the system using the primer pump. The system is primed when water comes out of the primer and pumping the handle becomes very difficult. 4. If the primer pump is mounted on the pressure side, close the isolating valve. 5. If fitted, switch the EPU (Engine Protection Unit) to the start mode. CAUTION Verify that everyone is clear of the tractor and the pump before you start the tractor. 6. Start the tractor and engage the PTO shaft. 7. Open the throttle to approximately 50% of the maximum PTO speed for the pump. The pump should slowly begin to build pressure and discharge water. 8. If the pump fails to discharge water, disengage the pump to the PTO drive shaft and stop the tractor. Re-prime the pump and try again. If the pump fails to 9. Check that the lever on the discharge priming valve rises, the pressure registers on the pressure gauge, and that the packing gland is dripping water. CAUTION During operation, water must drip from the packing gland at a slow, steady rate. The packing relies on water for cooling and lubrication. If water does not drip from the packing gland, stop the pump immediately and adjust the gland. 10. Allow the pipeline to fill slowly. Do NOT run the tractor above half speed until water is seen emerging from the distribution system continuously for two minutes without intermittent air discharge. CAUTION Do NOT increase the PTO speed until the pipeline is full of water. Filling the system slowly prevents the system from being damaged by water hammer, avoids overloading the tractor, and helps the pump keep its prime. 11. When the system has filled, increase the tractor PTO speed until the full operating pressure is reached. MAN072 09/08/09 13
Operation PTO Pumps CAUTION Do NOT operate the pump above the recommended speed. Maximum input speed of 540 or 1000 RPM is specified for each pump. How to Stop the PTO Pump 1. Slowly decrease the PTO speed. 2. Disengage the power to the PTO drive shaft. 3. Stop the tractor. 14 09/08/09 MAN072
PTO Pump Maintenance 4. Maintenance Regular Maintenance... 16 Before Performing Maintenance... 16 Maintenance Schedule... 16 Gearbox... 18 Primary Valve... 18 Priming Pump... 18 PTO Drive Shaft... 18 Wheels/Tires... 18 Packing Gland... 19 Winterizing... 19 Pump Body... 19 Water-Cooled Gearboxes... 19 PTO Drive Shaft... 20 Gearbox... 20 General Winterizing... 20 Troubleshooting... 21 MAN072 09/08/09 15
Maintenance PTO Pump Regular Maintenance We strongly recommend that you perform regular maintenance on your PTO Pump to help ensure efficient and safe operation. This section describes the maintenance that is needed to maintain your PTO pump and to provide you with years of reliable service. Before Performing Maintenance WARNING Failure to shut down the tractor before performing maintenance or lubrication could result in serious personal injury or damage to the machine. 1. Disengage the power to the PTO shaft. 2. Turn the tractor off and remove the keys. 3. Disconnect the PTO shaft. Maintenance Schedule The following page contains the maintenance schedule we strongly recommend that you follow to maintain your PTO pump at its safest and most efficient operation. 16 09/08/09 MAN072
PTO Pump Maintenance Maintenance Schedule Item Action Each Use Every Week of 20 Hours First Month or 50 Hours Interval Every 3 Months or 100 Hours Every 6 Months or 200 Hours Every Year or 600 hours Gearbox Check oil Change oil X X Primary Valve Apply oil to pivots Check valve seats X X Priming Pump Apply oil to pivots X Grease U- joints X Oil yoke push pins PTO Drive Shaft Apply oil to shield bearings X Separate and grease 2 halves of shaft X Wheels/tires Check pressure Grease bearings X X MAN072 09/08/09 17
Maintenance PTO Pump DANGER Always disengage power to the PTO shaft, turn the tractor off, remove the key, and disconnect the PTO shaft before servicing the pump. Failure to do so can result in serious personal injury or damage to the machine. Wheels/Tires Check the air pressure in the tires every three months or 100 hours, whichever comes first. The recommended tire pressure is 20 PSI. Gearbox Check the oil in the gearbox each time you use the PTO pump. Change the oil in the gearbox monthly or every 50 hours, which ever comes first. Replace the oil with a good quality SAE 90 gear oil. Primary Valve Apply oil to the primary valve s pivots weekly or every 20 hours, whichever comes first. Check the valve seats at the same time. Priming Pump Apply oil to the priming pump s pivots weekly or every 20 hours, whichever comes first. PTO Drive Shaft Every time you use the PTO pump, you need to do the following maintenance on the PTO drive shaft: Grease the U-joints Oil the yoke push pins Apply oil to the shield bearings Separate and grease the two halves of the shaft. 18 09/08/09 MAN072
PTO Pump Maintenance Packing Gland During the pump s operation, one drop of water must drip from the packing gland every 2-3 seconds. The packing relies on this water to cool and lubricate. If the water drips excessively, however, an air leak may form that will cause a loss in the pump s efficiency or prime. To adjust the amount of water dripping from the gland: DANGER Always disengage power to the PTO shaft, turn the tractor off, remove the key, and disconnect the PTO shaft before servicing the pump. Failure to do so can result in serious personal injury or damage to the machine. 1. If the water does not drip fast enough from the packing gland, loosen the two gland nuts evenly until the leak increases to a steady drip. 2. If water drips excessively from the packing gland, tighten the two gland nuts until the leak is reduced to a steady drip. 3. If the packing gland leaks excessively and the leak cannot be reduced by tightening the two gland nuts, add a new packing ring. 4. If there is insufficient room to add an additional ring, new packing should be installed. A new set of packing normally consists of five rings. Each ring is split. When you install the new rings, position the splits alternately at 180 degrees. Adjust the gland until water drips steadily. Winterizing During the winter months, take special care to maintain the pump in good condition. Follow the instructions for winterizing the pump parts to help prevent corrosion and freezing damage during winter storage. Pump Body 1. Remove the plug from the base of the pump body and drain all the water. 2. Rotate the impeller shaft by hand several times to release any trapped water. 3. Replace the plug and pour one pint of motor oil into the pump through the suction port. 4. Rotate the impeller shaft by hand about 10 times to coat the impeller with oil. 5. Remove the plug and allow the oil to drain. Replace the plug. Water-Cooled Gearboxes On pumps equipped with water-cooled gearboxes, the cooling lines must be drained to prevent damage due to water freezing in the line. We recommend that you drain these lines prior to putting oil in the pump body. 1. Disconnect the copper tubes from the lowest point on the pump body and blow out any water. 2. For additional protection, put anti-freeze into the lines using an oil can. 3. Re-connect the lines. MAN072 09/08/09 19
Maintenance PTO Pump PTO Drive Shaft 1. Remove the PTO shaft. 2. Lubricate all fittings. 3. Smear grease or oil onto the spine of each end yoke. 1. NOTE! If possible, cover the tires so that they will not be exposed to direct sunlight. Exposure to ultraviolet rays will cause damage to the rubber and shorten the life of the tires. Gearbox 1. Drain the oil and refill. 2. Rotate the gearbox input shaft several times to coat the gears with oil. 3. Coat the gearbox input shaft with grease or oil to prevent corrosion. General Winterizing Perform the following steps to prepare the PTO pump for winter. 1. Coat the outside of the packing gland with oil. 2. Grease the wheel bearings with a good quality wheel bearing grease. 3. Lubricate the priming valve. Wipe any excess oil off of the rubber seat. 4. Oil the priming pump pivot points and open the priming pump drain valve. 5. Cover the pump ports to keep dirt, dust, debris, and animals out. 6. Store the pump under cover in a clean, dry place. 7. Block the pump up to remove the weight from the tires. 8. Decrease air pressure in the tires to 10 PSI. 20 09/08/09 MAN072
PTO Pump Maintenance Troubleshooting Problem Cause Remedy Pump will not prime Air leak in suction piping. Look for holes, cracks, or loose connections and repair as needed. See Page Packing gland is loose. Tighten gland. 19 Excessive suction lift. Suction inlet blocked. Move pump closer to the water. Check inlet and clean out. Flow is too low Broken priming pump. Defective priming discharge valve. Suction inlet partially blocked. Suction screen/pipe too small. Impeller partially blocked. Pump speed too slow. Check priming pump and make necessary repairs. Check the priming valve discharge and make necessary repairs. Check the suction inlet and clean out. Check with your local dealer and replace as necessary. Examine the impeller and clean out. Increase the speed. Make sure the PTO is operating properly. Air entering pump through suction pipework or packing gland. Excessive suction lift. Check the pipe-work for leaks. Tighten the packing gland. Move the pump closer to the water. 19 MAN072 09/08/09 21
Maintenance PTO Pump Problem Cause Remedy See Page Pump speed too slow. Air entering through packing gland. Increase the speed. Make sure the PTO is operating properly. Check for leaks and tighten the packing gland. 19 Pressure is too low. Excessive suction lift. Move pump closer to the water. Impeller partially blocked. Examine the impeller and clean out. System demand exceeds the pump capacity. Check the system for large leaks. Check that the system demand (sprinkler nozzle sizes, etc.) matches the pump capacity. Pump speed is too high. Reduce speed to recommended maximum. Tractor PTO is defective. Service or replace the PTO as necessary. Pump requires too much power. Excessive PTO drive shaft misalignment. Pump gland is too tight. Re-align the tractor and pump. Loosen the gland and make necessary adjustments. 19 System demand exceeds pump capacity. Check the system for large leaks. Check that the system demand (sprinkler nozzle sizes, etc.) matches the pump capacity. 22 09/08/09 MAN072
PTO Pump Maintenance Problem Cause Remedy See Page Stops pumping. Severe vibration or noise. Air entering suction pipework causing pump to lose prime. Large air leak through packing gland. Suction inlet plugged. Water level is too low. Transmission failure. No oil in gearbox. Bearing failure. Suction lift too high. Partially blocked suction line or pump impeller. Flow rate too high or too low. Check for leaks in the pipework and repair. Tighten gland if possible. If necessary, replace the packing gland. Check suction inlet and clean out. Increase depth of water over suction strainer. Service transmission as needed. Fill gearbox with a good quality SAE 90 gear oil to level on dipstick. Service bearings. Lubricate or replace as needed. Move pump closer to the water. Check suction line and pump impeller. Clean out each as needed. Make sure the system demand matches the pump capacity. Adjust the system or change the pump as necessary. 19 MAN072 09/08/09 23
Maintenance PTO Pump Problem Cause Remedy See Page Excessive packing gland leak. Pump shaft worn. Pump shaft running off center due to bearing failure. Replace the pump shaft. Replace the bearings. Gland packing worn. Replace packing. 19 Gearbox overheats. Too little oil, too much oil, or wrong grade of oil. Gears damaged. Pump speed too high. Flow rate too high. Drain and flush gearbox. Fill with correct grade of oil (good quality SAE 90 gear oil). Replace gears. Reduce speed to recommended maximum speed. Make sure system demand matches pump capacity. Adjust the system or change the pump as necessary. 24 09/08/09 MAN072
PTO Pump Appendix Appendix PTO Drive Shaft Alignment... A 2 Diagrams... A - 3 MAN072 09/08/09 A - 1
Appendix PTO Pump PTO Drive Shaft Alignment The drive shaft for the 550 RPM PTO has a 1-3/8 6 spline attaching yoke. The shaft for the 1000 RPM has a 1-3/8-21 spline. Each yoke has a spring loaded locking pin that fits the groove in the tractor shaft. CAUTION Do NOT use adapters to attach a 550 RPM pump to a 1000 RPM PTO tractor. This could overload your pump and tractor engine or the pump speed increaser. This type of failure voids your pump warranty. Since irrigation pumping imposes a continuous load on the tractor and the engine unlike other operations, make sure the load on the tractor PTO does NOT exceed 75% of the available maximum belt horsepower output. If your tractor is older, use a lower percentage. Refer to the diagram below. All tractor PTO pumps are furnished with a drive line guard over the pump input shaft. These guards must be in place during operation. A - 2 09/08/09 MAN072
PTO Pump Appendix Diagrams MAN072 09/08/09 A - 3
Appendix PTO Pump A - 4 09/08/09 MAN072