YAMADA DP-10F Manuel utilisateur

MAINTENANCE MANUAL

YAMADA AIR-OPERATED DIAPHRAGM PUMPS

DP-10Fi

DP-20Fi

Doc. No. NDP 149M-06

WARNING

- For safety’s sake, be sure to read this maintenance manual thoroughly before starting

maintenance for this product. After reading the manual, keep it in an easy-to-access place so

that the user may refer to it whenever necessary.

This maintenance manual describes the items required for maintenance of the Yamada DP-Fi series

Diaphragm Pumps.

This document is based on the products that are manufactured in March 2011. Note that its contents are

subject to change as a result of specification changes to be made in future.

- Warnings and Cautions

To use this product safely, be sure to observe the contents of the following description. In this manual,

warnings and cautions are indicated by using symbols. These symbols are intended to prevent death or

serious injury that may be caused to the operator or those who are around the product and damage that

may be caused to the articles that are around the product, as well as to use the product safely and correctly.

Each symbol is indicated and has a meaning as shown below. Read the description with a good

understanding of its contents.

WARNING: This indicates the existence of potential hazard which, if not

avoided, will result in death or serious injury.

CAUTION : This indicates the existence of potential hazard which, if not

avoided, may result in bodily injury or in physical damage.

To indicate the contents of danger and damage, the following symbols are used together with the above

indications.

This symbol indicates an act that is prohibited (prohibition). The concrete contents of

prohibition are indicated by the side of the indication.

This symbol indicates the contents that must be observed. The concrete contents of

observance are indicated by the side of the indication.

WARNING

- Before starting the maintenance work, shut off the supply air and clean the pump. If air

pressure or residual liquid remains in the pump, damage or explosion may be caused to the

product or serious injury or death may be caused if it sticks on the eyes or skin or inhaled or

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

- When replacing parts, be sure to use the genuine parts or equivalents. Using parts other than

these parts may result in a fault.

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

CAUTION

- When it is indicated that dedicated tools should be used, be sure to use these dedicated tools,

otherwise the pump may be damaged.

- Check the weight of the pump by referring to 10.1 Main Specifications in the operation manual

and take extreme care when lifting it.

Table of Contents

· Warnings and Cautions

· Table of Contents

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

2. Tool and Others Required

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

2.2 Dedicated tools ··································································· 1

2.3 Others. ·············································································· 2

3. Ordering Replacement parts ················································· 2

4. Base

4.1 Removal ············································································ 3

4.2 Installation ········································································ 3

5. Valve Body and C Spool Valve Assembly

5.1 Removal ············································································ 4

■Valve body assembly·························································· 4

■Disassembling of the C Spool Valve ······································ 6

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

5.3 Installation ········································································ 8

6. Ball Valves and Valve Seats

6.1 Removal ············································································ 9

6.2 Inspection ·········································································10

6.3 Installation ·······································································10

7. Diaphragm and Center Rod

7.1 Removal ··········································································· 11

7.2 Inspection ·········································································13

7.3 Installation ·······································································13

8. Pilot Valve Assembly

8.1 Removal ···········································································15

8.2 Inspection ·········································································15

8.3 Installation ·······································································15

9. Retightening of Tie rods ·······················································16

1. Principles of operation

Liquid material chambers are located inside and air chambers are located outside of the DP-Fi

series pump.When compressed air is supplied to the air chamber “a” (see the left figure below) by the

switch valve of this pump, the center rod starts moving to the left to cause liquid in the liquid

material chamber “A” to be pushed out to the discharge port, and at the same time liquid is sucked

into the liquid material chamber “B”.

When the center rod moves full-stroke to the left, the switch valve is automatically switched,

compressed air is sent to the air chamber “b”, and the center rod moves to the right, that is, toward

the opposite direction (see the right figure).

As the result, liquid in the liquid material chamber “B” is pushed out to the discharge port, and at

the same time liquid is sucked into the liquid material chamber “A”.

Thorough repetition of this operation, liquid is repeatedly taken in and discharged out to construct

a diaphragm pump.

2. Tools and Others Required

2.1 General tools

・Socket wrenches 13 mm , 19 mm ・Flat head screw driver

・Open-end wrenches 13 mm , 19 mm ・Snap ring pliers

・Hexagonal wrench 6 mm

・ Plyer

2.2 Dedicated tools

①Valve cap remover (supplied)

Purpose: Removing the valve cap and

valve stopper.

(Part No. for DP-10Fi: 832516)

②Valve cap remover (Fi/□/R only supplied)

Purpose:

DP-10Fi, DP-20Fi: Removing the valve cap

DP-20Fi: valve stopper.

(Part No. for DP-20Fi: 832517)

③Guide holder remover (optional)

Purpose:

DP-10Fi, DP-20Fi: Removing the guide holder and spring seat.

(Part No. 832518)

Liquid material

chamber “B”

Air Chamber ”ｂ” Air Chamber “a” Air Chamber “ｂ”Air Chamber “a”

Liquid material

chamber “A”

Liquid material

chamber “B”

Liquid material

chamber “A”

④Sleeve remover (optional)

Purpose: Removing sleeves, valve seat and

funnel.

(Part No. 713148)

⑤Cap remover (optional)

Purpose: Removing a cap.

(Part No. 771132)

⑥ Ring Wrench

DP-10Fi/□/H (Part No. 832802)

DP-20Fi/□/H (Part No. 832803)

⑦Support Ring Wrench

DP-10Fi/□/H (Part No. 832804)

DP-20Fi/□/H (Part No. 832805)

2.3 Others.

・Assembly lubricating oil Fomblin®GR AR555 or equivalent

・Bolts M8 ×1.25×30 or larger

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.

4. Base

4.1 Removal（only Fi/□/R）

Follow the steps below to separate the pump main unit from the base.

・Remove the fixing screw (one). [Fig.4-1]

・Slide the pump main unit toward the fixing screw, then

raise and remove it from the base. [Fig.4-2]

4.2 Installation

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

disassembly.

5. Valve Body and C Spool Valve Assembly

5.1 Removal

■Valve body assembly（Fi/□/R）

・Remove the cap from each hexagon-headed bolt (part

“a”). [Fig.5-1]

・Remove the hexagon-headed bolts (four).

・Put the bolt (M8 × 1.25 × 30 or larger) on the tip of the

pin (part “b”), and screw it. Pull out the pin towards

the up direction to remove it.

＜NOTE＞

－To pull out a pin of the part “b”, use the hexagon-headed

bolt removed from the part “a”.

・Remove the valve body assembly and the piping blocks

A and B from the pump. [Fig.5-2]

・Remove the piping block assembly from the valve body

assembly.

・Use the dedicated tool ⑤(cap remover) to remove the

cap from the valve body assembly. [Fig.5-3]

・Use a plyer remove the C spool valve assembly.

[Fig.5-4]

・Use the dedicated tool ④(sleeve remover) to remove a

sleeve. [Fig.5-5]

■Valve body assembly（Fi/□/H）

・Remove air tube from fitting.〔Fig.5-6〕

・

Screw in bolt（Ｍ8×1.25×30）and pull up pin then remove

pin.

・Remove valve body from pump body.

・Remove air tube from fitting〔Fig.5-7〕

・Use the dedicated tool ⑤(Cap remover) to remove cap

from valve body assembly.〔Fig.5-8〕

・Use a plyer remove C Spool assembly. 〔Fig.5-9〕

・Use the dedicated tool ④(Sleeve remover) to remove

sleeve.

〔Fig.5-10〕

Fig.5-6

Fig.5-7

Fig.5-8

Fig.5-9

Fig.5-10

■Disassembling of the C Spool Valve

・Use a flat-blade screwdriver to raise the outside of the

C spring so that the outside can be opened, and remove

the C spring. [Fig.5-11 and 5-12]

＜NOTE＞

－When you remove the C spring, the arm is removed

also.

・Use the snap ring plyer to remove the interlocking

bush from the spool while opening and pushing the

groove of the interlocking bush. ［Fig.5-13 and 5-14］

＜NOTE＞

－Do not exert any excessive force to the spool.

－Do not open the groove of the interlocking bush

more widely than it has to.

－When you remove the interlocking bush, the spring

retaining cushion is removed also.

Fig.5-11

Fig.5-12

Fig.5-13

Fig.5-14

5.2 Inspection

・Spool

Measure the outside diameter, and if it is out of the

allowable range, replace the spool with a new one.

[Fig.5-15]

Allowable range of the spool

DP-10Fi/P/□

DP-20Fi/P/□φ15.73 ～φ15.80 mm

DP-10Fi/C/□

DP-20Fi/C/□φ15.77 ～φ15.80 mm

・Sleeve

Measure the inside diameter, and if it is out of the

allowable range, replace the sleeve with a new one. If

the sleeve is cracked or damaged, replace it. [Fig.5-16]

Allowable range of the Sleeve

DP-10Fi/P/□

DP-20Fi/P/□φ15.80 ～φ15.86 mm

DP-10Fi/C/□

DP-20Fi/C/□φ15.80 ～φ15.82 mm

・O rings

If the O ring is worn out or cracked, replace it with a

new one. [Fig.5-11]

＜NOTE＞

－Be sure to replace the spool and sleeve together as a

complete set.

・C spring

Measure the dimension shown on the left figure, and if

it is out of the allowable range, replace the C spring.

[Fig.5-17]

Allowable range of the C spring

25.9 ～26.5 mm

・Interlocking bush

Measure the dimension shown on the left figure, and if

it is out of the allowable range, replace the interlocking

bush with a new one. [Fig.5-18]

Usable range of Interlocking bush

Part to measure “a” 4.8 ～5.0 mm

Part to measure “b” 6.8 ～7.1 mm

・Arm

Measure the dimension shown on the left figure, and if

it is out of the allowable range, replace the arm with a

new one. [Fig.5-19]

Usable range of Arm

10.5 ～10.9 mm

・Spring bearing

If the spring bearing is worn out or cracked,

replace it with a new one. [Fig.5-20]

・Cushion

If the cushion is worn out or cracked, replace

it with a new one. [Fig.5-20]

Fig.5-15

Fig.5-16

Fig.5-17

Fig.5-18

Fig.5-19

Fig.5-20

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