Doc. No.
APP 030U-01
OPERATION MANUAL
250 TYPE HIGH VISCOSITY PUMP SERIES
MODEL No. 853869 SR250P40
MODEL No. 853870 SR250P55
WARNING
For safe operation, be sure to read this OPERATION MANUAL thoroughly before using the pump to
understand the “Warnings and Cautions” particularly. Be sure to keep this OPERATION MANUAL
handy for future reference.
Preface
This instruction manual describes how to use this machine properly and what care should be taken, intended
that it will serve you well without fault.
Before reading the manual, never operate the machine.
Read precautions carefully. Keep this manual handy.
If you find any questions, doubts, or problems in our machines, contact our distributors from which you made
a purchase.
If this instruction manual or caution labels are damaged or lost, buy other ones from which you made a
purchase. Save this manual and affix the labels properly.
Contents
1.
Purpose of use ·············································································································1
2. Warning / Caution ········································································································1
3.
Precautions ··················································································································1
4. Name of each section ··································································································3
5. Operating principle ·······································································································3
6.
Preparation for installation and use ·············································································4
7. Directions for use ·········································································································4
8. Maintenance and inspection ························································································5
8-1 Troubleshooting······································································································5
8-2 Maintenance and inspection ··················································································6
8-3 Consumable parts ··································································································6
8-4 Disassembly and assembly····················································································7
Separating pump assembly ···················································································7
Disassembling lower pump····················································································7
8-5 Component breakdown diagram············································································8
9.
Specification ·················································································································10
9-1
Specification ···········································································································10
9-2
External dimensions·······························································································10
9-3
Performance curves ·······························································································10
10. Limited Warranty ····································································································11
1. Purpose of use
Type 250, a high viscosity grease pump, has an air-powered pumping system used for transferring grease.
Since this machine has high discharge volume and pressure, it is best suitable for the situation that
voluminous grease supply in a short period of time is required continuously; such that grease is transferred
or it is simultaneously used in multiple ports branched from a piping.
This machine is designed to mount on a 200L-drum. We recommend that the product should be installed on
and used with a double elevator (853871) specially designed for it.
2. Warning / Caution
Warning and caution labels are affixed on this machine to call attention to your safe use.
Never fail to observe precautions to prevent any personal injury, physical damage, and accidents
WARNING This label indicates that mishandling may cause death or serious injury.
CAUTION This label indicates that mishandling may cause injury and physical damage.
NOTE：The above labels are intended to improve efficient operation and perform device maintenance.
3. Precautions
Be sure to observe warning and caution described below since they are very important.
[Service conditions]
CAUTION
Read precautions carefully before use
-Be sure you understand precautions for your safe and proper use.
Restrictions on handling
-Operators or administrators of this machine must never allow anyone without its knowledge to
manipulate it.
-If this instruction is damaged or lost, give us or our distributors an order for it.
[Installation and piping]
CAUTION
Stop operation
-If you feel something dangerous or find abnormality during operation, stop operating and eliminate the
cause before resuming.
Turn off pneumatic supply
-Be sure to turn off pneumatic supply before operation.
Install properly
-Install the product properly while observing the instructions for material and size of piping. Extreme
care should be taken to prevent leakage or damage.
1
[Directions for use]
WARNING
Understand this instruction manual before use.
-Those who are engaged in operation and maintenance must read this instruction manual carefully and
understand it completely before operating this products or pumps related to this product or performing
maintenance. Never operate this product before understanding the contents of the manual
completely.
Never use this machine for inapplicable purpose.
-If this machine is applied out of the specification of this machine or specified purpose, it may cause
personal injury or physical damage.
Use this product in compliance with product specification.
[Disassembly, maintenance, and inspection]
WARNING
Turn off pneumatic supply.
-If a device is operated with pneumatic supply on, materials may be regurgitated.
When operating, be sure to turn off pneumatic supply and stop the device.
Release internal pressure of enabled piping (for both air and material) before performing maintenance
and inspection.
No modification allowed.
-Modification to this machine may cause personal injury or malfunction.
Never make any modification to this machine.
-Some materials drained from this machine may be hazardous to you.
Be sure to drain it into a case or a tank.
Never drain it onto the ground directly.
Consumption time of consumable parts
-The useful lives of consumable parts may vary depending on type of materials and service conditions.
If basic performance seems to be degraded significantly, replace parts with new ones.
[Suspension, stop, and storage]
CAUTION
-When this machine is left unused for a long period or stopped, or after its operation is finished, or on
nighttimes and holidays, be sure to turn off its pneumatic supply and release the gun.
Then, release internal pressure of the piping and the hoses.
Keeping pneumatic supply on may damage gaskets and hoses, resulting in contamination of facilities
with grease. Secondary problems shall be attributable to users.
2
4．Name of each section
Air inlet
Air motor
Material discharge port
Lower pump
4-1 Package
Unpack the pump from the package. Check if there is any damage on it.
5．Operating principle
Yamada's air-powered pumps employ reciprocating motion system driven by compressed air.
It is comprised of two sections as illustrated at right; air motor section which drives
the pump and lower pump section which pump up material.
When compressed air, generated by the compressor, is fed into the air motor, the air
switching mechanism built in the air piston actuates vertical reciprocating motions.
The joint rod, joining the air piston inside the air motor and the piston inside the
Air motor
lower pump, transmits the movement to the piston inside the lower pump,
giving vertical reciprocating strokes.
Piston
Vertical reciprocating motions, generated by the lower pumps, feed material
into the lower pump.
Then, it is pumped out of the discharge port.
Connecting
rod
Lower pump
Fig.5.1
3
6．Preparation for installation and use
This machine is assembled onto the double elevator and
used as a unit. See attached instruction
manual for installation, directions for use,
and precautions in handling.
6-1. Since an in-plant inspection of this machine are
conducted using petrolic mineral oil before delivery,
a suitable solvent for your material must be used
to circulate up to the pump and piping outlet and
to clean inside the machine.
CAUTION
-NBR and PUR (urethane) are used for gaskets and
Bleeder valve
Open this valve when
the unit is placed on
the drum, and close it
completely after the air
is released.
O-rings, never use solvents which deteriorates them in
cleaning.
6-2. Open the bleeder valve on the lower pump.
NOTE
The air lift ascends and descends if it is directly connected
with piping, be sure to use flexible hoses.
7．Directions for use
CAUTION
-The maximum air pressure of this unit is 0.7MPa. Usage in a higher pressure may cause personal injury
and physical damage. Never exceed 0.7MPa when it is used. If pneumatic lines go beyond 0.7MPa,
use an air regulator to decompress it to 0.7MPa or lower. Just in case of malfunction of the air
regulator, connect a relief valve on the way of piping.
Establish 3 devices (a filter, a regulator, and a lubricator) on the branched location of the primary
pneumatic piping for every single pump.
-Never bring your face close to an outlet of activating pump. A high-pressure emission may freeze water
content, forming an ice. It may hurt you.
-The secondary problems, such as damage on air hoses and grease leakage from the
valves or guns due to neglect to shut off the pneumatic supply after stopping operation or during
nighttime, may be attributable to users.
-Never put your hands into 3 studs, joining the air motor with the lower pump.
The reciprocating plunger may pinch and hurt you.
-If the pump is caused malfunction or suspended, avoid careless disassembly. See (Checking failure and
troubleshooting) on page 5 to determine the circumstance. Never disassemble unnecessary spots.
-Never bring your face close to the port of the bleeder valve since material mixed with air may be
scattered.
-When this product is left unused for a long period, turn off its pneumatic supply and release residual
pressure.
7-1. Open the tap on the air regulator and turn its knob to the right (clockwise) slowly.
Make a light trial running to actuate the pump approximately at 8-10 strokes per minute.
7-2. A material released from the bleeder valve during operation.
At the beginning, air gets mixed. Actuate the pump until no air is mixed. When an appropriate material comes out,
close the tap on the bleeder valve.
7-3. The material is ready to use. Adjust pneumatic supply pressure to be suitable for service conditions.
4
NOTE
An air regulator adjusts pneumatic supply pressure to a pump, improving workability by minimizing useless
motions and increasing the life of a pump.
To adjust pneumatic pressure using an air regulator, turn it the right (clockwise) to increase pressure and to
the left (counterclockwise) to decrease.
8. Maintenance and inspection
8-1. Troubleshooting
Status
The pump does not
work.
Air leaks from the air
motor
Air leaks from the
silencer when the
pump stops.
Material is not
Sucked when it is
Carried for the first
time.
Possible causes
Troubleshooting / action
The compressor does not work.
The valve for pneumatic piping is closed.
Air pressure setting is lower than 0.2MPa.
Actuate the compressor.
Open the valve.
Increase air pressure setting at 0.2MPa or
higher.
Open the valve.
Provide an air filter on the pneumatic piping.
The valve for material discharge is closed.
A freezing occurs inside the silencer.
The O-ring on sliding section of the air piston is
worn out. (Air leaks from the silencer.)
The block (705693) inside the switching valve
(804355 or 804358) or the balls retaining the
block are worn out.
The switching pin (714446) is damaged.
The switching valve (804355 or 804358) or the
parts related to switching mechanism inside
the air motor (804354, 804357 or 804398) are
damaged.
The bonding section of the cushion (770549)
inside the switching valve peels off and falls out
of the slot.
Screws on part joint section are loosened.
O-rings or gaskets are damaged.
Foreign objects get caught in the block
(705693) inside the switching valve (804355
or 804358) and in the sliding section of the
switching seat (705688), seat section is worn
out, or the gasket (772331) is damaged.
Since the actuating speed of the pump is too
fast, the lower pump can not suck the material
in time.
(The valve inside the lower pump gets hard to
work.)
5
Replace parts.
Degrease and bond it again (Use quick-drying
adhesive for rubber and metal), or replace
parts.
Retighten malfunction spot or replace parts.
Replace parts or remove the foreign object.
Decrease air pressure setting and actuate the
pump approximately at 8-10 strokes per minute
until the material is sucked.
Material is not
pumped
The
pump does not stop
Material leaks from
the lower pump
Air is still mixed in
material even after
deflation.
When descent motion of the plunge is faster,
sheet for piston valve has defect (The seat
section is worn out or a foreign object gets in
the unit.), or the gasket is damaged.
When descent motion of the plunge is faster,
sheet for foot valve has defect (The seat
section is worn out or a foreign object gets in
the unit.), the gasket is damaged, or the shovel
rod is bent.
When descent motion of the plunge is faster,
since the actuating speed of the pump is too
fast, the lower pump can not suck the material
in time. (Inside the pump develops under
vacuum.)
Air leaks from material discharge piping.
Material leaks from parts joint section of the
lower pump(Screws on part joint section are
loosened. O-rings, backup rings, or gaskets
are damaged.)
Screws on part joint section are loosened.
O-rings, backup rings, or gaskets are
damaged.
Screws on suction piping are loosened. Poor
sealing.
Screws on part joint section of the lower pump
are loosened. O-rings, backup rings, or
gaskets are damaged.
Replace parts or remove the foreign object.
Decrease air pressure setting until the
symptoms described at left will be settled.
(Under current condition, the pressure adjusted
as above is the upper limit of normal operating
pressure.)
Retighten malfunction spot or replace parts.
Retighten malfunction spot or replace parts.
Retighten malfunction spot.
Reseal the unit.
Retighten malfunction spot or replace parts.
8-2. Maintenance and inspection
[Lubrication]
Refill the oil into the lubricator. Use turbine oil type 1 (No additives) ISO VG32.
8-3. Consumable parts
[Consumable parts]
Gaskets for pump and parts for sliding section will be worn. Inspection and replacement are required once a year.
6
8-4. Disassembly and assembly
WANING
-Gasoline is a high volatile fuel. Never use it for cleansing a pump. It may cause ignition or explosion.
-Before disassembling and inspecting this product, be sure to stop pneumatic supply, open outlet valve, and
release the pressure inside the pump.
-Since this product has considerable weight, handle it with extreme care.
-When cleansing parts, never use fluid corrosive to aluminum, copper alloy, and iron. And never apply solvent
deteriorating O-rings and the gaskets.
The air motor has almost trouble-free mechanism, free from disassembly.
Should there be any need for disassembly, contact our designated service offices.
[Separating pump assembly]
1) Activate the pump and cleanse the inside of the lower pump with an appropriate solvent.
2) To disassemble the pump assembly, unscrew 4 bolts fixing the pump assembly and the mounting bracket, then,
unscrew other 4 bolts fixing the inductor plate.
Since the pump assembly has considerable weight, handle it with extreme care.
[Disassembling lower pump]
1) Unscrew nuts fixing 3 joint rods.
2) Unscrew the union nuts and the bolts
for the bushing at the edge of the plunger
to dismount the lower pump.
3) Disjoin the discharge port and the bleeder
valve as shown in the figure 2. (Fig.2)
4) Push the plunger downward and extrude
the shovel section from the bottom of the pump
(inductor plate mounting section).
Then, unscrew the lock nut at the shovel
section to disjoin it.
5) Disconnect the foot valve housing out of
the suction tube.
Foot valve gets free to dismount.
6) Disconnect the suction tube out of the body.
7) Dismount the shovel rod from the piston valve,
disjoin the piston valve from the plunger, then,
extract the plunger out of the body.
8) Unscrewing the bolts fixing the ground section
of the body disjoins ground retainer through
U-gaskets.
9) After disassembling the lower pump,
check respective parts. If hazardous scratches,
Fig. 2
damage on the gaskets, or extreme abrasions
are found, replace applicable parts. Then, assemble
it again in reverse order to how it is disassembled.
[Disassembling air motor]
Since the air motor has difficulty of adjustment in assembly, if you identify a malfunction after reading "Checking failure
and troubleshooting" on page 5, ask our distributors from which you made a purchase or our sales offices for repair.
7
8-5. Part resolution chart
■853869
SR250P40 part resolution chart
No
1
2
3
4
5
6
6-1
6-2
6-3
6-4
6-5
6-9
6-10
6-11
6-12
6-13
6-16
6-17
6-18
6-19
6-20
6-21
6-22
6-23
6-24
6-26
6-27
6-28
6-29
6-30
6-32
6-33
6-34
6-35
6-36
6-37
6-38
6-39
6-40
6-41
6-42
6-43
6-44
6-45
6-46
6-48
6-49
6-50
6-51
6-52
6-53
6-54
6-55
6-56
6-57
6-58
6-59
7
8
8
PART No.
804357
791222
714994
627018
631426
804455
640040
715248
640037
685471
715298
685642
631422
715299
772831
685643
715300
643788
685644
685645
685646
681198
685367
685354
715301
685116
715302
715022
715023
715024
715303
685655
685455
640131
715304
685648
685649
772832
715305
685650
640017
632544
715027
715028
643669
713551
713552
713553
631420
681886
715306
701503
630340
701504
701505
701502
680083
791212
685750
DESCRIPTION
air motor assembly
label
stud
nut
spring washer
lower pump assembly
o ring
bushing
o ring
pin
plunger
bolt
spring washer
gland retainer
throat bearing
o ring
packing housing
backup ring
o ring
backup ring
u packing
street elbow
nipple
valve
body
backup ring
suction tube
valve stopper
spacer
valve seat
foot valve housing
o ring
pin
o ring
piston body
u packing
backup ring
wear ring
piston valve
o ring
o ring
pin
shovel rod
foot valve
backup ring
valve guide
valve plate
shovel
spring washer
nut
valve seat
washer
ball
spring
cap
valve body
union adapter
label
rivet
Q'TY
1
1
3
3
3
1
1
1
1
1
6
6
1
1
3
1
1
2
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
2
2
1
1
2
1
1
1
1
2
1
1
1
1
1
1
2
1
1
1
1
1
1
2
■853870
SR250P55 part resolution chart
9
No
1
2
3
4
5
6
6-1
6-2
6-3
6-4
6-5
6-9
6-10
6-11
6-12
6-13
6-16
6-17
6-18
6-19
6-20
6-21
6-22
6-23
6-24
6-26
6-27
6-28
6-29
6-30
6-31
6-32
6-33
6-34
6-35
6-36
6-37
6-38
6-39
6-40
6-41
6-42
6-43
6-44
6-45
6-46
6-48
6-49
6-50
6-51
6-52
6-53
6-54
6-55
6-56
6-57
6-58
6-59
7
8
PART No.
DESCRIPTION
804357 air motor assembly
791222 label
714994 stud
627018 nut
631426 spring washer
804456 lower pump assembly
640040 o ring
715248 bushing
640037 o ring
685471 pin
715307 plunger
685642 bolt
631422 spring washer
715308 gland retainer
772833 throat bearing
685643 o ring
715309 packing housing
643787 backup ring
685651 o ring
685652 backup ring
685653 u packing
681198 street elbow
685367 nipple
685354 valve
715310 body
685116 backup ring
715311 suction tube
715022 valve stopper
715023 spacer
715024 valve seat
685644 o ring
715312 foot valve housing
685655 o ring
685455 pin
684503 o ring
715313 piston body
685656 u packing
685657 backup ring
772834 wear ring
715314 piston valve
685650 o ring
640017 o ring
632544 pin
715027 shovel rod
715028 foot valve
643669 backup ring
713551 valve guide
713552 valve plate
713553 shovel
631420 spring washer
681886 nut
715306 valve seat
701503 washer
630340 ball
701504 spring
701505 cap
701502 valve body
680083 union adapter
791212 label
685750 rivet
Q'TY
1
1
3
3
3
1
1
1
1
1
6
6
1
1
3
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
2
2
1
1
2
1
1
1
1
2
1
1
1
1
1
1
2
1
1
1
1
1
1
2
9. Specifications
9-1.Specification
Product number
Model
853869
853870
SR250P40
SR250P55
40×1
55×1
Pump ratio
Material suction / discharge
Air connection
Suction port
A fixing flange designed for specific inductor plate prepared
Discharge port
G 1(F)
Supply port
NPT 3/4(F)
Working air pressure
0.2～0.7 MPa
Noise
Max. 82 dB(A)
Temperature range on
service condition
Temperature
0～70 ˚C
Material
0～80˚C
temperature
Discharge rate / stroke ※ 1
When service air
pressure ranging
0.3-0.6MPa is
released.
Discharge rate
Air consumption
345 mL
250 mL
25.0～26.4 L / min
17.6～20.4 L / min
2630～5100 L / min(ANR)
2650～5000 L / min(ANR)
Weight (pump only)
70 kg
※ 1 Discharge rate and stroke may vary depending on the service conditions.
9-2. External dimension
Model
Product number
A(mm)
B(mm)
SR250P40
853869
1351
910
SR250P55
853870
1351
910
9-3. Performance curves
NOTE
If desired discharge rate is within the gray zone on the right of the
charts below, continuous pump operation can not be recommended
10
10. Limited Warranty
1. Warranty period
This warranty will be valid for a period of 12 months after the date of purchase.
2. Warranty
If, during the warranty period, any of the material of the genuine parts of this product or the
workmanship of this product is found defective, and is so verified by our company, the servicing cost
will be fully born by our company.
3. Exclusion
Even during the warranty period, this warranty does not cover the following:
(1) Malfunction arising from use of parts other than manufacturer-specified genuine parts
(2) Malfunction arising from misuse or operating errors, or lack of storage or maintenance care
(3) Malfunction arising from use with a fluid that may cause corrosion, inflation or dissolution of the
component parts of the product
(4) Irregularity arising from repair made by other than by our firm, our regional office, dealer or
authorized service personnel
(5) Malfunction arising from modification of the product by other than authorized service personnel
(6) Wear-out of articles of consumable part such as valve seats, balls, o rings, tube.
(7) Malfunction and/or damage due to transportation, moving or such as fall of the product after
purchase.
(8) Malfunction and/or damage due to fire, earthquake, flood or other inevitability.
(9) Malfunction arising from use of compressed air that contains impurities or excessive moisture, o
use of gases or fluids other than the specified compressed air.
4. Parts
Parts for this product will be kept available for 5 years after discontinuation of production.
Once 5 years have elapsed after close of production, availability of parts for this product cannot be
guaranteed.
11
Manufactured by
YAMADA
CORPORATION
INTERNATIONAL DEPARTMENT
No.1-3, 1-Chome, Minami- Magome, Ohta-Ku, Tokyo, 143-8504, Japan
PHONE : +81-(0)3-3777-0241
FAX
: +81-(0)3-3777-0584
201108 APP030U