Manual No.

863E

Duplex Pump

Preventive maintenance manual

NIKKISO CO., LTD.

All contents of this document are the copyright of NIKKISO CO., LTD.

Contents

• Required tools for disassembly and assembly·· •••••••••••••••••••••••••••• ..,

• Pump removal procedure· •••••••••••••••••••••••••••••••••••••••••••••••• ··2

• Disassembly procedure·· ••••••••••••••••••••••••••••••••••••••••••••••••• ~

• Preventive maintenance parts· •••••••••••••••••••••••••••••••••••••••••••• .., 0

• Assembly procedure ..•••..•••..•••...•••..••...•••..•••...•••.•••..•••. ·-11

• Pum p installation •••••••••••••••••••••••••••••••••••••••••••••••••••••••• -17

• Operation checks· .••••..•••..•••..•••..•••..•••...•••..••..•••..••••..•• .., 9

+Ouplex pump position

+Required

tools

for

disassembly and assembly (1) 4 Pairs of forceps

(2) Phillips screw driver

(3) Hex box driver (7mm)

(4) Jeweler's screw driver (-) set (5) Waterproof sand paper (No.600-1000)

(6) Gauze

(7) High-vacuum grease

the position of the duplex pump is depend on the machine type)

Machine type Duplex pump
088-05 Front side
088-27 Right side Always switch OFF the main power during assembly/disassembly work.

1

1. Pump removal procedure CD. Remove the screw from the bracket which fixes the duplex pump with Phillips screw driver.

Bracket

Phillips screw driver

~. Pull out the duplex pump towards yourself.

Note: Watch out for the cables and silicone tube which are still connected to the pump

Before pulling out

After pulling out

@. Clamp 2 inlets and 2 outlets silicone tubes which are connected to the duplex pump with forceps.

Clamp 4 tubing

Note. If some places are difficult to clamp, move the duplex pump position to clamp.

Supply side (H1 side)

Drain side (H2 side)

2

@. Disconnect T-connectors of electrodes from

2 inlets and 2 outlets tube connectors of the duplex pump.

T-connectors for electrode

@. Disconnect the connector of electrode cable (transmitter) which is connected to the housing.

Electrode cable connector

®. Disconnect the connector of the motor cable.

Note: Hold the duplex pump in your hand, when motor cable is disconnected.

Electrode

Motor

Motor connector

3

Note: Ensure that not to bend the pins when the connector is disconnected

o: Remove the duplex pump from the equipment.

2. Disassembly procedure

CD, Rotate the nuts anticlockwise, and remove the nut, the tube connectors, poppet valve assemblies, and O-rinQs,

Nut

Housing

e· ... 1o~'~·-·'

.~fC... .-.- ~ .... , .""-:- .'

- =~·WJ~· _',~,~,

- -_ .. - '.'

I ~ 'I"

, 'W" '1'· I

t, r

, ",' , .': 'p.r ~ "

' .. '

• ~'J

Note: To collect the spillage,

follow the step1 above the bucket.

[Removed parts]

Outlet side/inlet side

(1) Nut

(2) Tube connector (outlet) (3) Poppet valve assembly (4) O-ring

(5) Tube connector (inlet)

4

~. Remove 2 hexagon bolts which fix the housing with hex box driver (7mm).

Hex box driver (7mm)

Housing Hexagon bolt Electrode cable

@. Pull the both side housings to remove them.

Housing

Housing

Cap seal

@. Remove the cap seals from the housing with jeweler's screw driver (-)

Cap seal

Jeweler's screw driver (-)

Clean inside the housing.

5

@. Remove the both rings from the body.

Ring

Note: Rotate the rings 90 degrees so that

both edge of the ring comes out of the body. Then hook your fingers on those edges and pull the ring to the outside to remove it.

®. Remove the tape bearing from the inner side of the ring with jeweler's screw driver (-)

After removing the tape bearing, clean the inner side of the ring with a piece of gauze.

(jJ Remove the 4 screws which fix the motor and gear box to the body.

Motor

Gearbox

6

Body

Nut

Note: The bracket is fixed to the body with the nut. Remove the bracket with hex box driver (7mm) and phillips screw driver or fingers to avoid both the screw and the nut rotate in same time.

Phillips screw driver

@. Pull out the motor and gear head assembly from the body.

Note: The motor and gear head assembly are fixed with seals.

It is not necessary to separate them.

®. Remove the block from the cam.

Note: The tip of the cam has been surface treated ..

Therefore do not clean it with waterproof sand paper. Only use a piece of gauze to clean the cam tip.

Cam

Block

Bracket

Hex box driver (7mm)

Body

Motor Gear head assembly

Note: The block is sometimes called as a slider.

7

@l. Remove the plunger from the body.

Plunger

@. Clean the plunger.

Clean inside the body with a piece of gauze.

Water proof sand paper

Surface

Channel for the block

Note: Remove dirt such as calcium carbonate and cap seal from the surface of the plunger with waterproof sand paper.

-++--- Clean the surface with a piece of gauze.

Black dart may remain even after the cleaning of the plunger surface. This dart is caused by cap seal particles trapped into the rough surface of the plunger, but these particle has no influence to the pump performance.

8

B. Preventive maintenance parts

Article name Article number Quantity Replacement cycle (hours)
Poppet valve assembly X04-504WOO 4 6000
O-ring R01-036B14 4 6000
Block (slider) X60-009BOO 1 6000
Cap seal S03-015A01 2 6000
Tape bearing B07-069AOO 2 12000 Note: The cap seal is constructed of the inner sealing and the outer O-ring.

If they are separated, reassemble them before use ..

9

14. Assembly Procedure

CD. Make the tape bearing circle and place it

in the ring. The tape bearing has no rotation.

Tape bearing

~. Insert the plunger into the ring with tape bearing, and twist it to give the shape to the tape bearing. Once tape bearing is shaped remove the plunger from the ring and give the shape to another tape bearing in the same way.

@. Insert the plunger into the body.

Note: Rotate the plunger so that the channel for the block faces the metal ring of the body.

Metal ring @. Place the block to the cam.

The channel for the block

10

Note: Ensure that the block is placed in the correct rotation

The side with bumps on both edges faces the plunger

@. Insert the gear head assembly with motor into the body which the plunger inserted.

Note: Insert so that the bearing of the gear head assembly

and body metal ring are parallel.

Note: Rotate the cam so that the inserted pin face the label side of the

-

-

Cam

Pin

Gearbox

®. Fix the motor and body with the 4 screws.

Philips screwdriver Fixing the label side

Screw (long)

Bracket

Fixing the bracket side

Note: At first, fix the two short screws on label side.

Then fix the two long screws on bracket side. Ensure that bracket rotation is correct.

11

o: Place the rings on the plunger.

Rings

Note: The ring has rotation which the deep side faces the inside.

When the ring is placed ensure that screw holes of ring and body are put together.

The deep side faces inside

Put screw holes together

@. Put on a little HIVAC-G (0 .. 01 to 0.02g/pc, a piece of rice size) the entire surface of the cap seals.

®. Place the cap seals to the both sides of plunger ..

Note: Ensure that cap seal is always placed on plunger side

not housing side.

Place the cap seal to the plunger side

12

@l. Place the housings.

Note .. Ensure that the housing is placed so that the arrow which shows flow direction is faces upward.

Ensure the arrow faces upward

I Note: Squeeze the housings with both hands.

@. Fix the hexagon bolts with hex box driver (7mm). Tighten the each bolt evenly and alternately.

Hexagon bolts

Note: Electrode cable is fixed with hexagon bolt which fixing the housing.

Ensure that cable is placed on the out side and crimp-type terminal face down ward and the connector is the connector side for better cable arrangement.

Crimp-type terminal faces down ward

13

@. Turn the pump upside down so that the bracket faces upward. Place the poppet valve assembly, o-rinq, and tube connector in this order to the inlet side of the housing, and tighten the nut with hand.

Note:. Ensure that the poppet valve assembly is placed in the correct direction.

@. Place the o-ring, poppet valve assembly, and tube connector in this order to the outlet side of the housing, and then tighten the nut with hand.

Note: Ensure that the poppet valve assembly is placed in the correct direction.

Note: Ensure that the outlet and inlet poppet valve assembly and o-rings are placed in right directions.

14

5. Pump installation

CD. Place the duplex pump to the equipment.

~. Connect the connector to the motor. The connector is designed to be connected only in right orientation.

@. Connect the T connectors for electrodes to the tube connectors and remove the forceps.

@. Place the duplex pump bracket into the hole of the flame.

Bracket

Hole

Bracket

I Note: Ensure that not to pinch any cables.

@. Fix the duplex pump bracket with screws ..

15

®. Connect the electrode cable connectors.

16

6. Operation check

CD. Rinse the dialysis machine, and check if there is any leakage or abnormal sounds. ~. Perform the balance test, and check if the test result is within the standard values.

* Balance test standard values: Within ±. 5mLl1 0 minutes

* For details see SERVICE-MODE instruction manual (OBB-05) "5.3 Relief valve (L) adjustment" or adjustment mode instruction manual "13.11 Balance check" (OBB-27). @. Perform OM test (OBB-05) or UFC self test (OBB-26), and check if no alarm is raised.

Note: If any of the check results are unacceptable or abnormal, do not use this machine for treatment..

17