YAMADA Custom-made System Guide

Grease Metering Packer Mobile Grease Metering System Grease Filling System Grease Metering Supply System for Railcar Axle Grease Metering System Automatic Grease Filling System Waste Oil Storage with Evacuation System Oil Management System for Quick Lube Shop

Basic concept

Yamada Custom-made System

Yamada offer custom-made system such as oil management system, fluid metering supply system, etc for mass-production plant. This engineering is based on our long experienced pump technology and metering technology. The metering technology can be categorized as below. Condition for system selection 1. Type of handling material 2. Characteristic and viscosity of material 3. Metering range 4. Quantity of preset value 5. Accuracy 6. Tact time 7. Cost etc. 2-2 PCL control type 2-1 Manual type

System-1 Cycle count method

YAMADA pneumatic Reciprocating pump and

Diaphragm pump is positive-displacement pump, which discharge fixed volume per cycle. By installing cycle sensor, batch operation is available.

System-3 Metering cylinder method

The liquid is filled in cylinder and then discharged from cylinder. As long as cylinder stroke is fixed, the discharge volume is fixed. Very accurate metering is available.

System-2 Flow meter method

The liquid flow is measured by flow meter. When the flow reaches to the preset value, the system stops liquid flow. There are several type of flow meter include trochoid meter, rotary meter and pulse meter. This system can be used from low viscosity material to high viscosity material, and the accuracy is around 0.5% to 1%. Manual type, semi-automatic type and fully automatic type can be selected. Relatively modest cost system can be build.

3-1 Material pressure control type

Material filled in cylinder is pushed by pressure from pump. Accuracy is around 0.5%. Charging is quick.

Basic concept
3-2 Air pressure control type
Material filled in cylinder is pushed by air cylinder. Accuracy is around 0.3%. Charging time is not quick as material pressure control type.

Yamada Custom-made System

System-5 Timer method

Liquid flow is controlled by timer. Simple and modest cost system can be built. However, working condition such as pressure, viscosity, specific gravity, etc. should be constant all the time.

System-4 Liquid level control method

The system can keep liquid level in fixed range. By using all pneumatic system, any type of liquid such as flammable controlled. liquid and strong chemicals can be

System-6 Electronic scale method

Material is scaled by electric scale. Very accurate metering is available. However, it requires time to complete the procedure.

INDEX
System-1 Cycle count method

Yamada Custom-made System

P4 P5

System-2 Flow meter method

System-3 Metering cylinder method

P6-7

System-4 Liquid level control method

P8-16

System-5 Timer method

P17-19

System-6 Electronic scale method

P20

Quick Oil Service System

P22-24 P25-26

Inquiry sheet, Company information 3

System-1 Cycle count method

Pump driver, Cycle counter
1) 2) 3) 803602 CE-124 diaphragm pump driver Solenoid valve (DC-24V) 804771 LCD cycle counter

Yamada Custom-made System

These equipments can count pump cycle and turn on/off the pump.

System-2 Flow meter method

Preset oil batch meter (electric type)
804536 LBM-P Preset batch meter The preset metering range is highly accurate from 0.1 to 999.0 liters. The large LCD has a 5-digit display and shows totals and flow rates etc. Max pressure: 6.5MPa Max flow rate: 30Liter/min

Yamada Custom-made System

Preset oil batch meter (analog type)

801429 LBM-60 Preset batch meter (60L) 802238 LBM-30 Preset batch meter (30L) 802237 LBM-16 Preset batch meter (16L) An oscillating batch meter that dispenses a preset quantity of oil. Min preset value: 1Liter Max pressure: 7MPa Max flow rate: 9Liter/min

Oil grip meter

802765 LBM-D Oil grip meter It has a 5-digit LCD, accurate to the third decimal place. The meter can display from 0.01 to 999.9 liter. Max pressure: 7MPa Max flow rate: 9Liter/min

Grease grip meter

853502 GMN-500 Preset grease batch meter It has a 4-digit LCD that shows grease flow. Max pressure: 55Mpa Max temperature: 60C

System-2 Flow meter method

Automatic oil metering supply system

Yamada Custom-made System

The oil flow is measured by trochoid flow meter. When the flow counter reaches preset value, the system stops the flow. The preset value can be set by the control panel.

Main component Diaphragm pump NDP-20BAN-D............1 Flow meter ..............................................1 Pneumatic flow control valve...................1 Main control unit......................................1

System-2 Flow meter method

Automatic grease metering supply system

Yamada Custom-made System

The grease flow is measured by trochoid flow meter. When the flow counter reaches preset value, the system stops the flow. The preset value can be set by the control panel.

Main component Grease pump unit SR-250P55 DWAL.....1 Flow meter ..............................................1 Pneumatic flow control valve...................2 Main control unit......................................1

System-3 Metering cylinder method

Metering gun KGK-100 series
Handy type dispenser with built-in metering cylinder. For grease model and For adhesive type can be selected.

Yamada Custom-made System

For grease (NBR packing) Model No. Model 851034 KGK-112 851035 KGK-114 851036 KGK-115 851037 KGK-116 851038 KGK-117 For adhesive (PTFE packing) Model No. Model 851039 KGK-112T 851040 KGK-114T 851041 KGK-115T 851042 KGK116T

Metering range 0.3 - 1mL 0.5 - 3mL 1 - 5mL 3 - 10mL 5 - 20mL

Metering range 0.3 - 1mL 0.5 - 3mL 1 - 5mL 3 - 10mL

A KGK-112, 112T KGK-114, 114T KGK-115, 115T KGK-116, 116T KGK-117

247mm 262mm 282mm 315mm 388mm

System-3 Metering cylinder method

Metering valve KGK-400 series
Stationary type dispenser with built-in metering cylinder. Only with pump and 3-port air switch, automatic metering system can be built. Without stroke sensor model and With stroke sensor model can be selected.

Yamada Custom-made System

Material is pushed by pump and fills up the cylinder. The cylinder also has pressure of material from behind.

The pilot air pushes down the valve. It closes material inlet and opens material outlet. The piston is pushed from behind, and discharges the material.

Material discharge finishes (the cylinder becomes empty).

When air is exhausted, the valve is pushed up. It closes material outlet and opens material inlet. The material fills up the cylinder again.

System-3 Metering cylinder method

KGK-400M series (without stroke sensor)

Yamada Custom-made System

For grease (NBR packing) Model No. Model 851055 KGK-401M 851056 KGK-402M 851057 KGK-404M 851058 KGK-405M 851059 KGK-406M 851060 KGK-407M 851061 KGK-408M For adhesive (PTFE packing) Model No. Model 851062 KGK-402T 851063 KGK-404T 851064 KGK-405T 851065 KGK-406T 851067 KGK-407T

Metering range 0.08 - 0.5mL 0.3 - 1mL 0.5 - 3mL 1 - 5mL 3 - 10mL 5 - 20mL 10 - 50mL

Metering range 0.3 - 1mL 0.5 - 3mL 1 - 5mL 3 - 10mL 10 - 20mL

A KGK-402 KGK-404 KGK-405 KGK-406 KGK-407

119mm 134mm 155mm 187mm 238mm

KGK-400MS series (with stroke sensor)

For grease (NBR packing) Model No. Model 850K214 KGK-402MS 850K215 KGK-404MS 850K143 KGK-405MS 850K151 KGK-406MS 850K222 KGK-407MS 850K221 KGK-408MS

Metering range 0.3 - 1mL 0.5 - 3mL 1 - 5mL 3 - 10mL 5 - 20mL 10 - 50mL

A KGK-402 KGK-404 KGK-405 KGK-406 KGK-407 KGK-408

135mm 170mm 196.5mm 237mm 259mm 326mm

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System-3 Metering cylinder method

High volume metering valve
High volume type is available upon request.

Yamada Custom-made System

Pneumatic open/close valve

803685 AF30M-15A (30MPa) 804001 AF20M-25A (20MPa) 804023 AF20M-25AS with sensor (20MPa) 850K109 Small flow valve (20MPa)

Pneumatic open/close valve for heavy viscosity material.

High pressure regulator

850K126 HPR-60 (1 6MPa) 850K157 HPR-130 (4 13MPa) 850K158 HPR-200 (8 20MPa)

Pressure regulator for heavy viscosity material. Max pressure: 42MPa

Restrictor
800K392 RR-25 Restrictor

It is used for multi-discharge point application. Max pressure: 25MPa

Pneumatic discharge nozzle

850K097 AN-20 Automatic nozzle It is used if discharge point is far from metering valve. Max pressure: 20MPa

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System-3 Metering cylinder method

Mobile grease metering supply unit
The simple unit consists of pump, metering valve and control box.

Yamada Custom-made System

SKR-110M50SAL & KGK-400 series

Metering valve and control box is mounted on to the SKR-110M50SAL grease pump unit. Foot switch and lower limit switch are equipped. Max discharge pressure: 30MPa Max flow rate: 1,200mL/min Max air consumption: 320NL/min Grease viscosity range: NLGI #0 - #3 Metering range: Refer to KGK-400 series

High pressure discharge hose with air tube, wiring for foot switch. It is used when installing the metering valve separate from the unit. Max pressure: 42MPa Size: 1/4

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System-3 Metering cylinder method

Yamada Custom-made System

SKR-55SAL & KGK-400 series

Metering valve and control box is mounted on to the SKR-55SAL grease pump unit. Foot switch and lower limit switch are equipped. Max discharge pressure: 35MPa Max flow rate: 300mL/min Max air consumption: 130NL/min Grease viscosity range: NLGI #0 - #1 Metering range: Refer to KGK-400 series

High pressure discharge hose with air tube, wiring for foot switch, and wiring for stroke sensor of grease metering valve. It is used when installing the metering valve separate from the unit. Max pressure: 42MPa Size: 1/4

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System-3 Metering cylinder method

Mobile grease metering supply unit (various metering amount)

Yamada Custom-made System

With multi-stroke metering cylinder, the unit can supply different volume of grease in a single procedure. The mobile design allows operation at any location.

Main component Grease pump unit Type 110 50x1 ...........1 Metering cylinder SP-1708......................1 Metering valve 800K943 .........................1

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System-3 Metering cylinder method

Multi-point grease metering supply system

Yamada Custom-made System

With two metering valves, the system can supply different volume of grease to two points in a single procedure. The system can be operated by control panel.

Main component Grease pump unit SR160M35ALS .........1 Metering valve KGK-406M......................1 Metering valve KGK-407M......................1 Main control unit .....................................1

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System-3 Metering cylinder method

Mobile grease metering supply unit for train axle

Yamada Custom-made System

The mobile type heavy duty unit allows supplying preset quantity of grease at any location.

Main component Grease pump unit SR160M35ALW-B .....1 Metering valve KGK-409MS ...................2 Hose, attachment set..............................2 Control box .............................................1

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System-4 Liquid level control method

Liquid level alarm series

Yamada Custom-made System

The all air-operated liquid level sensor can be used for any kind of liquid includes flammable liquid and chemicals. Low level alarm and High level alarm can be selected.

480007 Low level alarm (Single output) 480010 Low level alarm (Dual output)

480008 High level alarm (Single output) 480011 High level alarm (Dual output)

When liquid level reaches lower limit, it shuts off air supply to pump and whistles the alarm. All control is air-operated. Air pressure range: 0.25 0.7MPa Max air flow: 1,000NL/min at 0.5MPa Max liquid viscosity: 2,500cPs

When liquid level reaches higher limit, it shuts off air supply to pneumatic valve and whistles the alarm. All control is

air-operated. Air pressure range: 0.25 0.7MPa Max air flow: 1,000NL/min at 0.5MPa Max liquid viscosity: 2,500cPs

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System-4 Liquid level control method

Liquid level controller
480005 High-Low level controller

Yamada Custom-made System

It can keep liquid level between lower limit and higher limit. All control The all air-operated system can be used for any type of liquid includes flammable liquid and chemicals. Air pressure range: 0.3 0.7MPa Max air flow: 300NL/min at 0.7MPa Max liquid viscosity: 1,000cPs

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System-4 Liquid level control method

Multi liquid level controller
Multi-level control type is available upon request.

Yamada Custom-made System

100 liter waste oil tank

When the waste tank becomes full, pump evacuates the waste oil automatically. When the waste tank becomes empty, pump stops automatically. All control is air-operated.

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System-5 Timer method

Two-component mixing metering system
This system can mix two-component epoxy by fixed ratio and discharge by fixed volume. The pumps and hoses are heated. The system can be operated by control panel.

Yamada Custom-made System

Main component Material pump unit SR160P20-SP ..........1 Metering cylinder ....................................2 Washing pump........................................2 Main control unit .....................................1

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System-6 Electric scale method

Grease metering packing system for train axle

Yamada Custom-made System

This system can pack fixed volume of grease into large bearing after overhaul automatically.

Main component Grease pump unit................................... 1 Metering cylinder.................................... 1 Seal case press packer .......................... 1 Roller conveyer ...................................... 1 Electric scale unit ................................... 1

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Quick oil service system

Yamada Custom-made System

Super Oil Shop

Yamada offer Super Oil Shop, which is total quick oil service system. It also can connect to POS (Point of Sale) system. Yamada can offer various equipment such as oil/grease pump, hose reels, waste oil equipment, etc.

Oil hose reels

It allows effective use of floor space.

Oil tank with supply pump

The pump supply oil to hose reels. When the oil level is low, liquid level sensor warn the alarm.

Operator control panel

All control panels are connected to main computer.

Waste tank with evacuation pump

When the waste tank becomes full, the pump the pump evacuates waste oil.

Oil drain arm

It is installed at basement and receives waste oil.

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Quick oil service system

Yamada Custom-made System

The system is classified broadly in supply system and waste system. After waste oil removed from the vehicle, new oil is supplied to the vehicle. When all procedure finishes, receipt is issued from POS terminal.

1. Park the car in place Insert a membership card/prepaid card 2. Selection of oil menu Input oil type by keypad 3. Press oil removal button Removed amount is measured 4. Completion of oil removal Removed amount is displayed 5. Press oil supply button Supply amount is displayed. Automatic stop at same amount as removed amount 6. Checking of oil level by dipstick Adjustment is available by pressing supply button 7. Press finish button Data is downloaded to POS system 8. Changed oil amount/price on display Close an account

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Quick oil service system

Mobile oil supply unit

Yamada Custom-made System

Oil dispense bar

The oil dispense bar can dispense oil from 3 non-drip oil taps.

Oil / LLC dispense bar

The oil/LLC dispense bar can dispense oil and LLC from 2 non-drip taps.

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Inquiry sheet

Yamada Custom-made System

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Company information
Major customers
JFE Steel Corporation JTEKT Corporation KAJIMA CORPORATION Kanto Auto Works, Ltd. KATO WORKS CO., LTD. Kirin Brewery Co., Ltd. KOBE STEEL, LTD. Komatsu Ltd. Kubota Corporation Maeda Kiko Co., Ltd. Mazda Motor Corporation Ministry of Defence Hitachi Construction Machinery Co., Ltd. MITOKOGYO CO., LTD. MITSUBISHI HEAVY INDUSTRIES, LTD. Honda Motor Co., Ltd. INAX Corporation Mitsubishi Motors Corporation Ishikawajima-Harima Heavy Industries Co., Ltd. New Japan Radio Co., Ltd. ISUZU MOTORS LIMITED Nikkei Inc. IYASAKA LIMITED NIPPON STEEL CORPORATION Japan Airlines Corporation NIPPON OIL CORPORATION The Japan Automotive Muffler Association NISSAN MOTOR CO., LTD. Japan Railway Company NISSAN DIESEL MOTOR CO., LTD. All Nippon Airways Co., Ltd. Altia Hashimoto Co., Ltd. Asahi Kasei Coporation Asahi Shimbun Company ANZEN MOTOR CAR CO., LTD. BANZAI, LTD. Daihatsu Motor Co., Ltd. DAIKIN INDUSTRIES, ltd. FUJIFILM Corporation FUJI HEAVY INDUSTRIES Ltd. Hino Motors, Ltd. Hitachi, Ltd.

Yamada Custom-made System

NOK CORPORATION NSK Ltd. O-WELL CORPORATION Okuma Corporation SAPPORO BREWERIES LTD. SHIMIZU CORPORATION ShinMaywa Industries, Ltd. Sumitomo Metal Industries, Ltd. SEKISUI CHEMICAL CO., LTD.
SHIN CATERPILLAR MITSUBISHI LTD.

SUZUKI MOTOR CORPORATION TOYOTA MOTOR CORPORATION

TRUSCO NAKAYAMA CORPORATION

Tokyo Electron Limited Tokyu car corporation TOSHIBA CORPORATION TOTO LTD. TOYO INK MFG. CO., LTD. Yamaha Motor Co., Ltd. YAMAZEN CORPORATION YUASA TRADING CO., LTD.

Sagamihara Factory

Establish Lot area Building area Employee

1963 18,728 m 11,919 m 120 Main machineries

Machining center.................................... 4 NC lathe ................................................. 15 Milling machine ...................................... 3 Grinding machine ................................... 8 Drip machine .......................................... 1 Turret machine ....................................... 3 Center lathe............................................ 3 Drill press ............................................... 10

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INTERNATIONAL DEPARTMENT
No. 1-3, 1-Chome, Minami-Magome, Ohta-ku, Tokyo 143-8504 Japan Tel: +81-(0)3-3777-0241 Fax: +81-(0)3-3777-0584 E-mail: intl@yamadacorp.co.jp Web: www.yamadacorp.co.jp