YAMADA Global Series Bedienungsanleitung

MAINTENANCE MANUAL

G15 Series

Doc. No. NDP 497M-02

WARNING

▪For your own safety, be sure to read these procedures carefully before performing

maintenance on this product. After reading this document, be sure to keep it handy for future

reference.

These maintenance manuals cover what you should know about maintenance of the Yamada G15 Series

Diaphragm Pumps.

This edition is based on the standards for the August 2018 production run. Remember, the specifications are

always subject to change; therefore, some of the information in this edition may not apply to new

specifications.

·Warnings and Cautions

For safe use of this product, be sure to note the following: In this document, warnings and cautions are

indicated by symbols. These symbols are for those who will operate this product and for those who will be

nearby, for safe operation and for prevention of personal injury and property damage. The following warning

and caution symbols have the meanings described below. Be sure to remember their meanings.

If you ignore the warning described and operate the product in an

manner, there is danger of serious bodily injury or death.

If you ignore the caution described and operate the product in an

improper manner, there is danger of personal injury or property

damage.

Furthermore, to indicate the type of danger and damage, the following symbols are also used along with those

mentioned above:

This symbol indicates a DON'T, and will be accompanied by an explanation on something you

must not do.

This symbol indicates a DO, and will be accompanied by instructions on something you must

do in a certain situation.

WARNING

▪Before starting maintenance work, cut off the feed air and clean the pump. If air pressure or

residue remain in the pump, there is danger of explosion, or possible poisoning resulting in

serious injury or death if chemicals adhere to the skin or are accidentally swallowed.

(For details on cleaning the pump, refer to Chapter 6 of the Operation Manual.)

▪When replacing parts, be sure to use the recommended genuine parts or Equivalents. Use of other

parts may cause a malfunction of the product.

(Refer to Exploded View and Reminder to order correct item on the separate sheets.)

CAUTION

▪When it is instructed that special tools must be used, be sure to use the specified tools. Otherwise,

the pump may be damaged.

▪Refer to 10.1 "Specifications" in the Operation Manual. Also, remember that the pump is heavy,

and extreme care must be taken when lifting it.

WARNING :

CAUTION :

Table of Contents

·Warnings and Cautions

·Table of Contents

1.Principles of operation···························································1

2.Tools, etc.

2.1 General tools ·······································································1

2.2 Special tools ········································································1

2.3 Misc.··················································································1

3.Ordering Replacement parts···················································1

4.Balls, Valve seats

4.1 Removal ·············································································2

4.2 Inspection ···········································································4

4.3 Installation···········································································4

5.Diaphragm and Center rod

5.1 Removal ·············································································5

5.2 Inspection ···········································································7

5.3 Installation···········································································7

6.Guide bush

6.1 Removal ·············································································8

6.2 Inspection ···········································································9

6.3 Installation···········································································9

7.Spool assembly and Sleeve

7.1 Removal ··········································································· 10

7.2 Inspection ········································································· 12

7.3 Installation········································································· 12

8.Retightening of Tie rods ····················································· 13

1. Principles of operation

There are two diaphragms fixed to the center rod, one at each end. When compressed air is supplied to air

chamber b (right side, see Fig.1.1), the center rod moves to the right, the material in material chamber B is

pushed out, and at the same time material is sucked into material chamber A.

When the center rod is moved full-stroke to the right, the air switch valve is switched, compressed air is sent

to air chamber a (left side, see Fig.1.2), and the center rod moves to the left. The material in material

chamber A is pushed out, and at the same time material is sucked into material chamber B.

Through repetition of this operation, material is repeatedly taken in and discharged out.

2. Tools, etc.

2.1 General tools

· Socket wrenches 10 mm（A_, S_, P_）, 12 mm（P_）,

13 mm（A_, S_）, 17 mm（A_, S_）

· Open-end wrenches 10 mm（A_, S_）, 12 mm（P_）, 13 mm（A_, S_）,

17 mm（A_, S_）, 22 mm（P_）

· Hexagonal box wrenches 5 mm

· Phillips head screw driver（P_）

· Pliers（P_）

2.2 Special tools (sold separately)

· Cap and disk remover（A_, S_）· Sleeve remover

Purpose: Removing the cap Purpose: For removing sleeves

2.3 Misc.

· Assembly oil Turbine oil none addition class 1(equivalent ISO VG32 grade)

· Grease Urea grease grade (NLGI) No.2

· Thread locking agent Equivalent to LOCTITE® 222

3. Ordering Replacement parts

For accurate and speedy shipment of parts, be sure to order the right parts for your model to distributor.

Indicate the part numbers, descriptions, and quantities.

Fig.1.1 Fig.1.2

Fig.2.1 Fig.2.2

(Part No. 771132) (Part No. 713148)

4. Balls, Valve seats

4.1 Removal

■A_, S_ Type

▪Remove 4 mounting bolts from upper manifold and remove

the manifold. [Fig.4.1]

▪Remove the O ring, valve stopper, ball, valve seat. [Fig.4.2]

▪Turn over the main body assembly. [Fig.4.3]

▪Remove 4 mounting bolts from lower manifold and remove

the base and the manifold. [Fig.4.3]

▪Remove the O ring, valve seat, ball, valve stopper. [Fig.4.4]

Fig.4.1

Fig.4.2

Fig.4.3

Fig.4.4

■P_ Type

▪Remove 4 mounting bolts from upper manifold A and remove

the manifold A. [Fig.4.5]

▪Remove the Ball, valve seat A, valve seat B, O ring. [Fig.4.6]

▪Turn over the main body assembly. [Fig.4.7]

▪Remove 4 mounting bolts from lower manifold B and remove

the manifold B. [Fig.4.7]

▪Remove the O ring, valve seat B, valve seat A, ball. [Fig.4.8]

Fig.4.5

Fig.4.6

Fig.4.7

Fig.4.8

4.2 Inspection

▪Ball [Fig.4.9]

Measure the outside diameter, and if it is outside the usable

range, replace the ball.

Usable range of Ball

Sø0.669 ~ Sø0.760 in {Sø17.0 ~ Sø19.3 mm}

▪O ring

If O ring is worn out or cracked, replace it.

Replace the PTFE O ring regardless of its condition.

■A_, S_ Type

▪Valve seat [Fig.4.10]

Measure the dimension shown at left, and if it is outside the

usable range, replace the valve seat.

Usable range of Valve seat

0.102 ~ 0.225 in {2.6 ~ 5.7 mm}

■P_ Type

▪Valve seat A [Fig.4.11]

Measure the dimension shown at left, and if it is outside the

usable range, replace the valve seat A.

Usable range of Valve seat A

0.055 ~ 0.071 in {1.4 ~ 1.8 mm}

▪Valve seat B [Fig.4.12]

Measure the dimension shown at left, and if it is outside the

usable range, replace the valve seat B.

Usable range of Valve seat B

0.177 ~ 0.256 in {4.5 ~ 6.5 mm}

4.3 Installation

For installation, see [Exploded View] on the separate sheet and install in the reverse order of disassembly.

Tightening torque for manifold retainer bolts or nuts

AN, AS, SN, SS 105 in-lbf {12 N-m}

AT, ST 160 in-lbf {18 N-m}

PS, PT 89 in-lbf {10 N-m}

<NOTE>

▪Make sure there is no dust on the seal surface and the seal

is not damaged.

Fig.4.11

Fig.4.12

Fig.4.9

Fig.4.10

5. Diaphragm and Center rod

5.1 Removal

■A_, S_ Type

▪Remove the O ring, valve stopper, ball, valve seat (see

[4.1 Removal]).

▪Remove the 12 retainer bolts from the out chamber, and

remove the out chamber. [Fig.5.1]

▪Remove the nuts on both sides of the center rod. [Fig.5.2]

▪After the nuts on one side have been removed, remove the

center disk and diaphragm. Remove the diaphragm, center

disk and center rod from the opposite side of the main body.

▪Remove the center disk on both sides of the center rod.

[Fig.5.3]

▪After the center disk on one side have been removed,

remove the center disk and diaphragm. Remove the

diaphragm, center disk and center rod from the opposite side

of the main body.

▪Put the cloth between the vise and the center rod to prevent

the part get scratched. [Fig.5.4]

▪Fix the center rod, and then;

A_ type: remove the nut

S_ type: remove the center disk

▪Remove the coned disk spring (only A_ Type), center disk

and diaphragm from center rod.

A_ Type

S_ Type

Fig.5.1

Fig.5.2

Fig.5.3

Fig.5.4

Fig.5.5

Fig.5.6

Fig.5.7

■P_ Type

▪Remove the ball, valve seat A, valve seat B, O ring. (see [4.1

Removal]).

▪Remove the 16 retainer bolts from the out chamber, and

remove the out chamber. [Fig.5.5]

▪Remove the center disk on both sides of the center rod.

[Fig.5.6]

▪After the center disk on one side have been removed using

the spanner 22 mm etc., remove the center disk, diaphragm

and backup diaphragm (only PT Type).

Remove the diaphragm, backup diaphragm (only PT Type),

center disk and center rod from the opposite side of the main

body.

▪Put the cloth between the vise and the center rod to prevent

the part get scratched.

▪Fix the center rod, and remove the center disk. [Fig.5.7]

▪Remove the diaphragm, backup diaphragm (only PT Type)

and center disk.

5.2 Inspection

▪Diaphragm

If the diaphragm is worn out or damaged, replace it.

New replace just one diaphragm.

Guideline of diaphragm life

A_, S_ NBR, PTFE 10,000,000 cycle

TPO 15,000,000 cycle

PTFE

（Including backup diaphragm）7,000,000 cycle

TPO 10,000,000 cycle

▪Center rod [Fig.5.8]

Measure the diameter, and if it is outside the usable range,

replace the center rod.

Usable range of center rod

Ø0.6280 ~ ø0.6299 in {ø15.95 ~ ø16.00 mm}

5.3 Installation

For installation, see [Exploded View] on the separate sheet and install in the reverse order of disassembly.

■A_, S_ Type

▪Apply grease to the center rod, and insert it into the main

body.

▪Keep the convex side to the outside for diaphragm.

▪For the model with PTFE diaphragm, put the O rings into

both side of the diaphragms. (cf. Fig.5.9, Fig.5.10).

▪A_ type: Tighten the nuts.

▪S_ type: Apply screw glue on the thread of center rod, then

tighten the center disks.

▪Assemble the out chamber. Bolts should not be fully

tightened at this point.

▪Place the pump on flat surface, stand the pump upright and

tighten all the bolts fully.

Tightening torque for center rod and out chamber

Center rod Out chamber

160 in-lbf {18 N-m} 105 in-lbf {12 N-m}

<NOTE>

▪Make sure there is no dust on the seal surface in order to

prevent seal damaged.

▪Replace the PTFE O ring by new one.

▪Tighten the bolts that balance should be equal from both side

on diagonal line with even torque.

Fig.5.8

Fig.5.10

S_ Type

Fig.5.9

A_ Type

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