Operatioo, Service &

Parts Manual

YWE
Piston Pump
P200,P250

YWE Sdn Bhd

KualaLumpur
MALAYSIA
 LIMITED
VTA RRAN TY

YWE SDN BHD, the manufacturer of the Piston Pump, warrants this product to be
freed from defects in material and workmanship, under normal use and service, for
a period of six (6) months from date of purchase and subject to the following
provisions:

THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY OTHER

WARRANTIES, EXPRESSED OR IMPLIED OF MANUFACTURER,
INCLUDING ANY WARRANTY OF MERCHANTABILITY OR OF FITNESS
FOR A PARTICULAR PURPOSE. It is made only to the initial user and any
liability whatsoever to any other party is expressly disclaimed.

This warranty is limited to repair or replacement with new or remanufactured parts

that appear to Manufacturer to have been defective in material or workmanship
and does not include any installation or transportation costs nor consequential
claims of any type.

This warranty does not apply to products, which in the judgment of Manufacturer
have been altered or modified after shipment from the factory, or to products,
which have been subjected to misuse or accident.

The responsibility of Manufacturer with respect to any parts or components

purchased by Manufacturer from others for incorporation into Manufacturer's
product shall not exceed the responsibility or expressed warranties made by such
supptiers to Manufacturer.

All claims against this Warranty shall be submiffed in writing. The defective part
or parts are to be retumed for inspection, transportation charges prepaid before any
replacement is made.

YWE SDN BHD

 TABLE OF CONTENTS

1. General Descriptions

2. Specifications

3. Operation

4. Service & Maintenance

5. Parts Replacement

1. General Descriptions: -
The P250 is a simple, lightweight and reliable single piston pump generally used
for wash boring in soil investigation. It is usually supplied with a clutch, ball valves
(rubber valves optional) and is mounted on a steel drag skid with a 6HP diesel
engine. An air chamber is also provided to reduce surging. The pump gives long
dependable service when the maintenance and servicing instructions are followed.

2. Specifications: -

Type: - Single piston double acting

DischargePressure: -Z}kglcm2
Displacement: - 0.42lhev.
Stroke: - 70mm
Speed: - 200rpm
Vatve type: - O4Imm steelball (rubbervalve optional)
Bore: - 63.5mm
Sucfion Port: - 50mm
Delivery Port: - 38mm
Power Unit: - Yanmar Diesel Engine TF70
Weight - 60kgs (bare pump)
- 198kgs (complete assembly)
I)imension: - 1,500Lx510Wx800H
(with skid)

Remarks: Actual specificafions may have slightly changed to incorporate new

improvements.
3. Operation: -
Those remarks or procedures highlighted in CAPITALS should be observed each
time the pump is started.

Installation :-
Wherever possible the pump should be placed or anchored securely on a level
ground.

Suction: -
The pump witl lift a suction head of 6 metres, however, to avoid losing its prime, a
foot valve should be used when the suction lift is in excess of 4 metres.
When making up the suction line, all pipefittings should be airtight. Drive a stake,
to whieh the strainer may be tied, into the boffom of the water or suspend the
strainer from a tloating object.
A suction screen with t.5mm mesh should be used for water and one with 4 -5mm
mesh for mud.

THE SUCTION STRAINER MUST BE KEPT CLEAN AT ALL TIMES.

Discharge: -
The pump should be protected by a relief valve immediately at the discharge
opening. This should be followed by a by-pass valve and then a check valve.

THE PUMP WILL NOT START AGAINST A PRESSURE HEAD, SO BE

SURE THE CLUTCH IS FREED BEFORE STARTING THE PUMP.

Priming: -
THE PUMP SHOULD BE PRIMED IF TT TIAS NOT BEEN OPERATED
FOR MORE TIIAN T2 HOURS. THIS IS IMPORTANT AS A YBRY FEW
DRY STROKES WILL RUIN THE PISTON RUBBERS.
To prime the pump, remove the two square-head plugs from the top of the fluid
chamber and flll thru these hotes while slowly turmng the pump by hand.

Engine: -
FOLLO\ry THE MANUFACTURERS TNSTRUCTIONS.

Drainins Pump: -
To drain the pump, remove two plugs from the bottom of the cylinder. Disconnect
the suction and discharge line and turn the pump slowly a few times by hand.
4. Service & Maintenance
Lubrication: -
Make sure the oil level in the crankcase is up to the brass plug in the end crankcase
cover at all times.
Drain by removing two plugs, both at the bottom of crankcase and gear case
respectively, and refill the crankcase (filler plug on top of crankcase) every 20
shifts. For normal operating conditions, a good quality SAE40 oil or gear oil of
ISO viscosity 90 should be used.
Grease the two clutch shifter bronze pieces every shift.
Grease the vee pulley bearings once every 30 shifts.

Belt Tension: -
Be sure that the slacked belts are not caused by the loosening of bolts securing the
engine to the wooden base blocks.
A rough guide for belt tension is such that, for every 100mm length of span of the
belt, the amount of sag should be about 2mm when pressed with a finger applying
about 5kgf at the centre of the span. For example, if belt span is 700mm, the sag
should be about 14mm.
It must be noted that over-tensioned belts strain the supporting bearings
unnecessary, and may lead to premature wear and failure.

Bearing Adjustment: -
These taper bearings are adjusted by removal or addition of shims under the
crankshaft bearing cover and pinion shaft bearing retainer.

Piston & Rod Rubbers: -

When there is a leak due to wear on the piston rod and its packing rubbeq tighten
the gland nut a little.
The piston rubbers also, can be slightly expanded to take up some wear by
tightening the piston locknut.
Crosshead: -
When replacing the crosshead seal, the irregularities on the shank of the crosshead
can be skimmed off on a lathe. Horvever, if this amount exceeds 0.6mm on
diameter (i.e. The shank diameter becomes less than 43.85mm), the undersized
seal should be used. The maximum amount that can be removed from the shank
when using the undersized seal is about lmm on diameter.

Cleaning: -
The pump should be washed out thoroughly immediately after pumping cement or
corrosive fluids.

Storage 0f Pump: -
When preparing a pump for long term storage the following items require special
attention:
1. Drain pump thoroughly.
2. Flush and refill pump crankcase.
3. If pump is equipped with a steel liner, remove the piston and grease liner.
4. Grease valve balls and seats

Failure To Pump: -
If the pump fails to deliver its rated volume and pressure examine it for the
following faults: -
l. Check for loose transmission belts.
2. Suction Line: Check for air leaks, collapsed hose or clogged strainer.
3. Open pumps head and check for stuck valves and blown gaskets.
4. Also, check for grooved surfaces on the bridges of the valve plate, fluid chamber
and cylinder.
5. Check for worn valve balls and seats, and examine the amount of "bounce"(see
Parts Replacement below) for the valve balls.
6. Check for wom piston rod or loosen rod rubber.
7. Inspect cylinder for worn piston rubber or grooved liner.
8. Check for leaking relief valve.
9. Check for vibrations, which could possibly cause the valve balls to bounce and
unable to create suction.
Note: -
To quickly bring a lightly grooved valve plate back into service at site; seal the
grooves with a fast drying epoxy readily available in the market. The valve plate
should eventually be repair welded or replaced
5. Parts Replacement

Valve Assembly: -
(i) Ball yalve type: -
In a new valve assembly, the valve balls should have approximately 3mm of
"bounce" in the fluid chamber. This may be checked by first, putting the fluid
chamber over the yalve plate assembly and then pushing the valve balls from
underneath the valve seats.
When this valving movement exceeds 7mm, check for wear on the valve balls,
valve seats and fluid chamber. The wear on the bumpers of the fluid chamber
should not exceed 1.5mm deep. The valving response has a direct effect on the
flow rate.
The worn fluid chamber could either be repaired (by welding) or replaced. All the
otherworn parts must be replaced.

(ii) Rubber valve type: -

A new valve assembly (seat, valve stem and valve rubber) should have
approximately 2.5mm clearance between the bridge of the valve seat and the
shoulder of the valve stem. This may be checked by applying pressure to the valve
stem nut and when this clearance is less than 0.5mm, it is an indication of a worn
valve stem, valve seat or valve rubber. The worn parts should then be replaced.

Note: -
When tightening valve stem nut, do not use excessive force; as this will dish the
valve rubber.

Crankshaft: -
Worn crankshaft can be re-machined or re-ground to make use of the undersized
split bearings available off the shelf. They come undersized in increment of 0.010",
to the maximum of 0.060" (l.52mm). Bearing sizes outside this range will have to
be specially turned.

Piston Rod: -
When assembling the piston rod to the crosshead, screw the piston rod in so that
there is a maximum 5mm of thread showing. The locknut must be properly
tightened to avoid the threads of the crosshead from being stripped.

Gaskets: -
When installing new gaskets, check carefully to see that their cuttings match the
internal bridging on the mating parts. Make sure that the surfaces are clean and
tighten down the head bolts evenly.

6
Piston Assemblies: -
When making up piston assembly, the piston locknut should be tightened securely.
To facilitate entry of the rubber piston assembly into the liner, they should be
coated with soap, gel or silicone (spray). Try not to use oil or grease, as some
piston rubbers are not totally oil resistant.
It may be easier to make up the piston assembly inside the cylinder. However, care
must be taken not to over tighten the locknut and seized the piston. Check it by
(engaging the clutch and) cranking the engine slowly a few times by hand.

Liner Assemblies: -
Steel liner: -
A 10 ton hydraulic press is required to remove the liner, which is press-fit. As the
cylinder is made of aluminum, the bore could be slightly enlarged after a few liner
replacement. In this case, use liner with increased interference or apply sleeve
retainer compound (e.g. Loctite 603 or OCi 8641) before re-assembling.

Ceramic liner: -
The liner is 'glued' to the cylinder with the use of a sleeve retainer compound, e.g.
Loctite 603 or OCi 8641 The assembly can be dismantled by pressing or heating
the cylinder to temperatures above 150 C.

Pressure Gauge: -
Ordinary oil resistant rubber sheet may be used as diaphragm. In this case, the
diaphragm should be dished slightly downwards before the fasteners are secured.
This is to counter the effects of stretching the diaphragm when it is subjected to
pressure, and hence introduce errors into the pressure readings.

7
Theoretical Delivery

100

90

80

70
.c
E
60
cf
o
E 50
(tr
b
o 40
6
o
30

20

10

0
00 1 000 1 500 2000
Revolution per minute (RPM) of prime mover

RPM of Yanmar Diesel Engine TF70 - 2,4}0rpm (max.)

RPM of motor - 1,450rpm
Pulley Ratio - 4.5:8
Gear Ratio - l:6

1ru
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MODEL PzOO & P25O

10
Pressure Gauqe Retief Valve

ttutch & PuIGy

11
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12
Ref. Part Name Qtv. Remarks
N0.
Srankcase Assemblv
1 lrankcase 1 c/w Ref. Nos. 10 & 11

2 lrankcase Bearinq Cover 1

3 nspection Plate 1 c/w Ref. No. 6

4 3asket (lnspection Plate) 1

5 lex. Bolt & Nut 2 112" x 2" BSW c/w washers

b 3rass Pluq 1 1/4" BSPT
7 Shim (Crankcase Cover) As Req'd 0.006" thick
7a Shim (Crankcase Cover) As Req'd 0.012" thick
7b Shim (Crankcase Cover) As Reo'd 0.020" thick
8 lex. bolt 10 5/16" x 1" BSW
o Sprino Washer 10 5/',l6"
10 ripe Pluq 1 1'' BSPT
11 rioe Pluo 2 1/2" BSPT
12 lrankshaft 1

13 lonnectinq Rod Bolt 2 5/16" x 2 1/2" UNF

14 lonnectino Rod Nut 2 5i16" UNF
16 lapered Bearinq Cup 2 14276 - for model Mo clutch
17 lapered Bearino Cone 2 141254 - for modelMo clutch
17a laoered Bearino fin set) 2 30306 - for model with clutch

Reduction Gear Assemblv

'18 3ear Case 1 c/w Ref. Nos. 23, 27 & 47
18a 3ear Case 1 c/w Ref. Nos. 23, 27 & 47 - for model
with clutch
19 lex. Bolt & Nut o 5/16" x1 114" BSW
20 Sprino Washer 12 5/16"
21 fuoodruff Kev 1 114" X1"
22 -ock Nut 1 1t'
23 3utton Screw 2 114" x 1/4" BSW
24 3ear 1

25 lex. Bolt 7 5/16" x 1" BSW

26 jprino Washer 7 5/'16"
27 Stud 1 5/16" x 3" BSW
28 fhrust Washer 1 1 114" lD
29 fapered Bearinq Cup 1 15250X - for both models
30 fapered Bearinq Cone 1 15100 - for both models
31 fhrust Washer I 1" lD

13
Ref. Part Name atv. Remarks
N0.
32 Sear Case cover I
32a Sear Case cover I lor modelwith clutch
33 lover Gasket 1

34 3earino Retainer 1 - for modelMo clutch

34a 3earinq Retainer 1 - for modelwith clutch
35 3earino Shim As Req'd - for modelMo clutch
35a 3earino Shim As Req'd - for model with clutch
36 lex. Bolt 2 5/16" x3l4" BSW
37 Sprinq Washer 3 5/16"
38 /Voodruff Kev 1 114" x1"
39 rlain Washer 1

40 Self Lockinq Nut 1 3/4" UNF

41 rinion Shaft 1 - for modelMo clutch
41a rinion Shaft 1 - for model wrth clutch
42 )il Seal 1 1 114" x2 1116" x 3/8"
42a fil Seal 1 30 x 50 x 8 - for model with clutch
,l
43 fapered Bearino Cone 14125A - for model Wo clutch
44 fapered Bearino Cup 1 14276 - for model Mo clutch
44a fapered Bearino (in set) 1 30306 - for modelwith clutch
47 3rass Pluo 2 1/4" BSPT
48 fowel Pin J 3/8"dia.x11/8"

Connecting Rod & Crosshead Assembly

49 lonnectino Rod 1 ciw Ref. Nos.13.14 & 54
51 Split Bearino 1 1 82561-STD
tl tt I
1 1 82561-010 (0.010" undersized)
tl rt tl
1 1 82561-020 "
(0.020" '|,

ll tl tt
1 1 82561-030 "
(0.030" '|,

il[il
1 1 82561-040 "
(0.040" '|,

il[[
1 (0.050" "
1 82561-050 '|,

ilil[
1 182561-060(0.060" " " )
52 turist Pin 1

53 lrosshead I c/w Ref, Nos. 55 & 56

54 lonnectino Rod Bush 1
LL
/Vrist Pin Screw 1 114" x 1" BSW
56 jprino Washer 1 1t4"
57 lrosshead Seal 1 Consists of Ref. Nos. 57a & 57c
57 -1 lrosshead Seal I Undersized, consists 57b & 57c
57a lrosshead Seal Caoe 1 Normal size

14
Ref. Part Name Qtv. Remarks
N0.
57b lrosshead Seal Caoe 1 Undersized
57c //iper Seal 1 8600-01750-4181
58 leflector 1

Piston Rod & Stuffing Box

59 riston Rod Locknut 1 5/8" BSW - Brass
60 riston Rod 1

61 riston Locknut 1 1/2" UNF

62 Sland Washer 1

63 3land 1

64 3land Rubber Gasket 1

65 3land Nut 1

oo riston Rod Rubber 1

o/ iubber Collar 1

Piston Assembly
73 3rass Piston 1 consists of Ref. Nos. 75, 76 &77
74 :iston Rubber 2
75 >iston Bodv 1

76 riston Follower 1

77 3ackino Plate 1

Cylinder Assembly
78 lvlinder 1 c/w Ref 79,82,86. 87. 88. 89. 90.
112 & 113
79 lvlinder Stud 7 112" x5114" BSW
80 lvlinder Cover 1

81 lvlinder Cover Gasket 1

82 lvlinder Cover Stud 4 112" x1 3l4" BSW

83 -{ex. Nut 4 1/2" BSW
84 Sorino Washer 4 112"
85 -'lex. Bolt 2 112" x1 1l4" BSW ciw washers
86 3rass Pluq 2 1/4" BSPT
87 Jex. Nut 5 1/2" BSW - reduced hex. size
88 3rass Washer 5 112"
89 Sland Stud 5 112" x2112" BSW
90 lvlinder Liner 1 Hardened Steel
91 lvlinder Liner 1 Ceramic
92 3. l. Bush 1 2" to 1 1/2" BSPT (not shown)

15
Ref. Part Name atv. Remarks
N0.

ilalve Plate Assembly

93 /alve Plate Complete 1 consists of Ref. Nos. 94 & 95 - for
use with rubber valve
94 /alve Plate 1

95 r/alve Seat 4 Bronze

96 /alve Plate Gasket [op) 1

97 r/alve Plate Gasket (Bottom) 1

100
'/alve Plate Comolete
1 consists of Ref. Nos. 101 & 102 - for
use with ball valve
'101 r/alve Plate 1

102 r/alve Seat 4

Ualve Assembly
103 Steel Ball 4 1 5/8" Dia.
104 Valve Assemblv (Bronze) 4 consists of Ref. Nos. 106, 107, 1OTa,
108 & 109
105 Valve Sprino 4
106 Valve Stem 4
107 Valve Stem Nut 4
1O7a Valve Siem Washer 4
108 Valve Stem Pin 4
109 Valve Rubber 4

Fluid Chamber Assembly

110 luid Chamber 1

111 rioe Pluo 1 1" BSPT

112 -lex. Nut 7 1/2" BSW
113 3rass Washer 7 1t2"
114 ripe Pluo 2 1/2" BSPT (not shown)
115 G. l. Bush 1 1 112" to '1" BSPT (not shown)

Air Chamber Assembly

116 Air Chamber Assemblv 1 Consists of Ref. Nos. 1 17 , 118 &1 19
117 Air Chamber 1

118 Pioe Pluo 1 1" BSPT

119 rioe Nioole 1 1" BSPT

16
Ref. Part Name Qtv. Remarks
N0.
Relief Valve Assembly
120 Relief Valve Assemblv 1 consists of Ref. Nos. 121, 122. 123.
124.125.126.127 &128
121 /alve Bodv 1

122 )lunqer 1

123 Sorino 1

124 [hrust Washer 1

125 3rass Nut 1

126 -ock Nut 1 1/2" UNC

127 \diustino Screw 1 112"x2 1/2"UNC
128 ?ubber Boot 1

Clutch & Pulley Assemblv .( for moc lel with clutch)

I

130 (ev 2 5/16" x1 112"

131 Slidinq Clutch doq 1

132 ixed Clutch doo 1

133 Srease Nipple & Adaptor 2

134 3ronze Piece- 2
135 llutch Shifter 1 C/w S.S. Wedoe
136 rivot Bolt 1

137 3all Bearino 62O0Z 1

138 3all Bearino 6206 I

139 3earinq Cover 1

140 -ock Washer 1 M86

141 -ock Nut 1 AN6
142 Srease Nioole 1 1/4" UNF
143 lirclip 1 A30
144 3earinq Soacer 1

145 lex. Bolt I 5/16" x3l4" BSW

146 Sprinq Washer o 5/16"
147 10" Vee Pullev 1

147a 3" Vee Pullev 1

skid
149 skid 1

150 3lock Guide (rear) 1

151 Block Guide (front) 1

152 Olamp Set 2 c/w Ref No. 153

17
Ref. Part Name atv. Remarks
N0.
153 lex. Bolt & Nut 2 112" x 4 112" BSW c/w washers
154 /Uooden Block 2
155 lex Bolt & Nut 4 112" x1 114" BSW c/w washers
156 lex. Bolt & Nut 2 5/16" x 1" BSW c/w s. washer
157 3elt Cover I
158 -lex. Bolt 1 5/16 x 3/4" BSW c/w s. washer
159 llutch Shifter Stand 1

160 -lex. Bolt & Nut 1 112x1 1/4" BSW c/w s. washer
161 Vee Belt 875 2 for 10" pulley (not shown)
161a Vee Belt B72 2 for 8" pullev (not shown)

Pressure Gauge Assembly

162 Pressure Gauqe Assemblv 1

163 Pioe Nioole 1 1" to 3/4" BSPT

164 3auoe protector (bottom halfl 1

165 Jiaohraom 1

166 -lex. Bolt & Nut I 5/'16" x 1" BSW ciw s. washer
167 3lvcerin
168 3auoe orotector (too halfl ,l

169 rressure Gauoe 1 4Okolcm2

18
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