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Centrafugal Pumps - Instr Manual
Centrafugal Pumps - Instr Manual
CENTRIFUGAL PUMPS
INSTRUCTION MANUAL
IMO-9439319
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Contents
Safety Instructions···························································· 1
1. Scope of Application 2
2. Transport 2
3. Prevention of Vibration · ·2
4. Installation 2
5. Piping ··················2
6. Connection· · · · · · · ·2
7. Operation 4
8. Maintenance
9. Inspection
1O. Troubles and Remedies
5
6
14
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• CENTRIFUGAL PUMPS
Safety Instructions
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ROTATING - ROLLED IN, BIT, PINCHED
indicates a potentially hazardous and SPILLED (contacted things).
situation which, if not avoided, could result in
death or serious injury.
Iif', CAUTION I
indicates a potentially hazardous
situation which, if not avoided, may result in
minor or moderate injury. LhCAUTION
OPERATION and MANIPULATION
ID. NOTICE I .00 NOT TOUCH or contact to SEALING
part or HOT parts while the pump is IN
indicates a potentially hazardous OPERATION.
situation which, if not avoided, may result in HOT - BURNED and INJURED
damaging or defecting a product. It will be
only used for protecting the property, but not INSPECTION and MAINTENANCE
for personal safety. .When OVERHAULING the pump, carefully
Footnote: ANSi Z 535 handle the HEAVY weighted parts:
especially, fitting a HANGING WIRE.
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1
• CENTRIFUGAL PUMPS
1. Scope of Application 6. Connection
This manual is applicable to centrifugal On completing installation, alignment •
pumps in general horizontal, vertical and must be checked and care must be taken so
selfpriming. that no misalignment occurs, readjustment
must be made carefully by loosening bolts in
each part.
2. Transport
a. Horizontal pump
In transport it Is necessary to proceed
as follows: It is desirable that adjustment be made by
insert liner between common bedplate and
a. When lifting, pay attention to the weight pump foundation base, but if
lifted and the method of using wires. necessary,liner can be placed between
b. Be careful to avoid damage to accessories common bedplate and motor base.
such as piping, valves, cocks, etc. b. Vertical pump
Adjustment is made by placing liner
3. Prevention of Vibration between motor and motor base.
In order to avoid vibration of pump and
piping, pay sufficient attention to the 6.1 In case of Flexible Coupling
reinforcement of pump foundation and piping
supports. 6.1 .1 Case when alignment is checked by •
disconnecting pump and motor.
a. As shown in the figure, after removing
4. Installation coupling bolts, check alignment by
Installation, pay attention as follows: measuring parallel and angular
a. Pump foundation must be rigid and strong. misalignment at 4 point. 90' apart, on the
coupling periphery.
b. Considering operation and overhaul. give as
wide space as possible.
c. Installation face must be horizontal. Fig. 1
Cantering by dial gage
5. Piping
~ ~-
Sufficient attention must be given to
piping since it has great effect on pump
performance.
a. Suction pipe must be as short as possible.
Clearance gage
b. Suction pipe must be free from air pocket
or air invasion.
c. Valves on the suction side must be
guarded against air invasion through the
gland.
d. Flanges connecting to the suction and
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discharge nozzles should be matched
correctly in order to avoid disturbance of This method is used chiefly at the time of
pump alignment when flange bolts are repair and intermediary as well as periodic
unduly tightened. inspection, but in the case of checkup after
e. Precautions must be taken so that new installation and piping, use of a dial
expansion and contraction due to gage is preferable.
temperature and weight of piping and
valves may not abnormally affect the pump.
f. Interior of the piping must be thoroughly
cleaned.
g. Strainer should be installed on the suction
side.
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• CENTRIFUGAL PUMPS
b. Check alignment according to the Table ,.
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6.2 In case of Rigid Coupling.
The Table 2 below shows CD the
Table'
allowable value of run-out of shaft center
Motor output Coupling Coupling end between Impelier shaft and motor shaft when
kW periphery(mm) face(mm) Impeller shaft and motor are connected, and
® the value of run-out of Impeller shaft
Below 37 Below 0.05 Below 0.1 0 center from the casing center when Impeller
shaft and motor are connected.
Above 37 Below 0.07 Below 0.16
Table 2
c. Confirm the rotating direction of the motor.
Run-out of shaft Run-out of center
d. Fit the coupling bolts. Motor output center between of Impeller from
e. Turn by hands to check if it turns smoothly. kW Impeller and motor casing center(mm)
shaft (mm)
f. Take care to avoid rust or damage on the
coupling periphery and face. Below 37 Below 0.03 BeiowO.03
6. '.2 Case when alignment is checked with Above 37 Below 0.05 Below 0.05
pump and motor coupled.
• a. For measurement on the shaft coupling
periphery, a dial gage is fixed on the motor
end coupling periphery and the pump end Shaft alignment is measured by the
coupling is given one complete turning. follwing manner
The value is going to be half of the
a. Connect motor and shaft and fix dial
difference of the highest and the lowest
gage on the motor flange, and turn the
value, which must comply with the value in
shaft once. The value is going to be
the Table-'.
half of the difference of the highest and
b. For measurement on the coupling end face. the lowest value.
the coupling is given one compiete turning
b. Connect motor and shaft and fix dial
as above at specified points using a
gage on the edge of the shaft. Set the
thickness gauge, etc., and the difference
point of the dial gage on the inner
between maximum and minimum readings
surface of casing ring and turn the shaft
is taken as the value of measurement.
once. The value is going to be half of
,.
which must comply with the value in Table
the indicator reading as shown in a.
c. For others, the procedures shown in 6. , . 1. Fig. 2
• 3
note: Exercise care not to damage motor when you
carry out the above.
• CENTRIFUGAL PUMPS
7. Operation
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7.2 Operation
Operation after installation or a. Start motor. but firstly ON and OFF should
reassembly must be carried out in the be repeated once or twice to confirm that
following order: there's no abnormal condition, when
operating the pump.
7.1 Preparation before operation b. When pump revolutions and pressure have
a. Open the air vent valve on top of the risen. open gradually the valve on the
casing and fill the casing with water until it discharge side until the pressure drops
comes out of the vent. down to the specified pressure.
b. In case of the reservoir-type self-priming c. Avoid absoluteiy dry operation. especially
pump (Model EHS and TMS type), fill the be careful when a mechanical seal is used.
casing with water by removing the plug on Even though a vacuum pump is provided.
top of the casing. stop the pump if self-priming (Model EHS
However. after the first starting there is no type) is not effected with in 5 minutes.
need of pouring if water remains in the d. The bearing for pump and motor of stand-
casing. by pump or pump that is not operated for
c. In case of the self-priming pump with a long time will be caused a fretting
phenomenon by the vibration so that there
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vacuum pump. fill water into the supply
water tank. is need to hand turning of pump once per a
week. If there is stand-by pump, there is
d. Open fully the valve on the suction side need changeover operation of pumps about
and close completely that on the discharge once per two (2) weeks.
side.
e. In case of the self-priming pump (Model 7.3 Stopping
EHS type), open a slightly the valve on the
discharge side in order to discharge the a. Close the valve on the discharge side.
separated air without close completely its b. Stop the motor.
valve. c. When the pump stops suddenly during
f. Be sure of bearing lubricant. operation, turn off the switch first and then
g. Turn the pump shaft by hand to see close the valve on the discharge side.
whether it turns smoothly.
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• CENTRIFUGAL PUMPS
8. Maintenance k. In the case of automatic operation under
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If the bearing case can be felt by hand
and etc.. the pump should be cleaned by
safely there is no fear, otherwise, install a
fresh water enough and kept by carefully
thermometer to measure the temperature.
Keep the permissible bearing temperature
at "ambient temperature plus 40'C or liquid
temperature plus 20'C"
d. Since excessive greasing can result in
overheat, grease up while operation by
taking off the exhaust plug This, however,
does not apply where greased bearings are
used.
e. Be sure to keep small amount of
continuous leakage through the gland.
which must be in the form of drops. Too
much tightening of the packing will cause
premature wear of the shaft and
overheating. (See par.9.5)
f. When a mechanical seal is used, there is
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almost no leakage, so if continuous
leakage occurs, trace it cause.
g. Never throttle the valve on the suction
side. Adjust the flow by means of the valve
on the discharge side.
h. Never operate the pump continuously
with the valve closed on the discharge
side, otherwise the rise of the water
temperature in the casing will cause
seizure.
i. See whether the stand by pump is
reversing due to the leakage of it non-
return valve.
j. In the case of a pump with automatic
starting and stopping device, such as
hydrophor system pay attention to the
pressure at the time of starting. and if the
cycle is too much, take measures such as
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adjustment of air amount, level, etc.
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• CENTRIFUGAL PUMPS
inspection periodically in the following way,
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9. Inspection but since it varies according to the method of
mounting, place of installation and liquid
9.1 Periodic Inspection handled, it is preferable that the operator
Excepting the case of abnormal should make a final plan of inspection in
conditions. it is desirable to carry out accordance with conditions.
Table 3
Period
Location Details Every 3 Every 6 Every 12 Every 4
months months months or years or
BOOOh 20000h
Replace lubricant
*Replace lubricant first time in 3 months after
operation start up.
Roiler bearing *Type of lubricant: 0
. Lubricant: Turbine ISO VG46, or equivalent
. Grease: Roller bearing grease Type 1 No. 2, or equivalent.
For greesed bearings. replace them with new items.
Check up sliding surfaces for points of contact and
Submerged
line
bearing
iniury. Measure inside diameter and if this is about
double than foilow list.
diameter
30-50
50-BO
BO-120
clearance by metal (in diameter)
0.OB-0.10
0.10-0.15
0.15-0.25
0
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Check up condition of fitting and amount of leak.
Gland Packing Renew it if leak is too much. 0
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Check up surface damage and condition of deterioration.
Renew it if deformed. 0
"0" ring
Renew it. 0
Check UP wear and condition of corrosion of ail parts,
and measure sliding faces in contact with casing rings
and a bore of casing rings. Based on the Table 4 sea clean
Impeiler (Clearances Between Impeiler Mouth and Casing Ring). water water
renew casing rings, if clearances were off from Limit 0 0
Clearance in Service.
Replace grease.
*Replace grease first time in one month after operation
start up, or 500 hours operation.
•
Gear coupling *Type of grease: 0
JIS K 2220 central lubrication grease Type 4 No. 1.
ar equivalent.
*Grease amount: See Table 5.
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• CENTRIFUGAL PUMPS
Table 4
• Dia. of
Sliding Face
Clearances Between Impeller Mouth and Casing Ring
Limit Clearance
in Service (Repi.)
Over Up to ® ® © @
30 50 0.27-0.38 0.40-0.51 0.35-0.46 0.50-0.61 1.5
50 80 0.30-0.42 0.45-0.57 0.40-0.57 0.55-0.67 1.6
80 120 0.35-0.50 0.50-0.65 0.45-0.60 0.60-0.75 1.9
120 180 0.40-0.57 0.55-0.72 0.55-0.72 0.70-0.87 2.0
Table 5
Grease Amount in Gear Coupling
Models Grease Amount (g)
NSE-103 29
Note 1. The number of hours in the previous
-1 15 57 page is the hours of operation time.
-125 70 Note 2. For the pump casing processing sea
water. its internal surface shall be
-137 90 coated. if it is made of cast iron. during
•
-160 (S) 168 the pump is open (tar epoxy resin
coating).
-175 175
-190 206
-224 313
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• CENTRIFUGAL PUMPS
9.2 Overhaul 9.5 Other Instructions
When overhauling the pump attention a. Gland Packing •
must be paid as follows: a- 1 Assembling Instructions (Division
a. Understand the construction well by Tightening)
referring to the assembly drawing and (1) Set the cut end of packing to fit in.
make no mistake in the order of overhaul. and check if it is inserted smoothly by
b. When separating sockets and parting hand while stretching its back.
faces. use push bolts and wooden (2) Insert one packing first to the extent
hammers. and never apply force with chisel of depth. and set the old packing
and drivers. instead of tools. and tighten them by
c. When removing the rotating element. take the nut on gland.
care to avoid damage on sliding faces and (3) Insert another packing and tighten it in
machined surfaces. the same manner as above (to such
Particularly. never damage mechanical seal an extent that the shaft can turn by
mating faces. hand.
d. When removing rotating parts from the · Full compression of packings on inner
shaft. draw off each one carefully after side will make the sealing effect
removing anti-rotation device. better and prevent two or more
e. Long parts such as shaft should be packings from turning at one time. so •
handled carefully so that it may not bend. that no bearing resulting from coerce
tightening will be applied on the
f. Handie parts carefully. arranging them on packing. Also. in general. tightening
sheets of paper or cloth in good order. of the packings by using the gland will
g. At overhauling. put suitable marks as much make the inner packings within the
as possible to avoid mistakes when packing box have lower shaft bearings.
reassembling. in which case. therefore. a tightening
force tends to be ineffective. Such
9.3 Checkup being the case. the packings at the
inner part should be compressed
Measure each sliding part and take sufficiently when they are inserted.
steps according to manufacturer's standard.
· The cut end of each packing should
not be located at the same point. but
9.4 Assembly should be apart by 120 degrees.
Carry out assembly. reversing the order (4) Then. insert the air side packing
of disassembly and paying attention as carefully. and tighten the gland nut by
follows: hand together (finger tight).
· Take care not to tighten the gland
a. Remove dust and stain from each part by
one-sidedly and also not to have it in •
washing it thoroughly with kerosene. Repair
contact with the shaft.
it if damage is found.
(5) Operate the pump for an initial run (30
b. Fit anti-rotation device perfectly in each
min.) while paying attention to any
rotating part if necessary.
irregularity. e.g. leak from the gland.
c. When fitting parts with match marks. be generation of heat or sound. Then.
sure to follow them. tighten the nut little by little for a
d. Install the mechanical seal carefully and proper leak amount. When the
confirm its movement by hand after operation has become stable. take
installation. care for the gland nut not to become
e. Insert each packing rings in good order loose.
softly one by one from the bottom,
staggering each joint by 90· or 120· .
(Refer to 9.5)
f. Check the center of shaft (see Item 6).
g. Turn the shaft by hand to see whether it
turns smoothly.
h. Check that the amount of lubricant is
appropriate. As for the amount, refer to the
lubricant list in "Specification of Supply". •
8
• CENTRIFUGAL PUMPS
a-2 Reference Leak Amount (4) Reference Leak Amount
In operation In standstill
•
a drop falls from a thread-like form.
suction pressure is reduced by the
amount of resistance In the suction
pipeline, and also the turning effort
arising from operation will be applied,
so that the leak amount is smaller
than that in standstill.
. When the leak amount in standstill is
not permissible, shut the suction
valve, and open it before operation.
a-3 Troubleshooting
Table 7
· Re-install packings.
· Fluid is slurry. · Provide a lantern ring to feed
water from outside.
· Too little leak. · Refer to "Reference Leak Amount".
•
9
• CENTRIFUGAL PUMPS
b. Mechanical Seal
b- 1 Initial Leak
It is ideal that the profile of clearance in
the sliding surface is always kept parallel and
flat. However. it is difficult to keep such a
profile due to the effects of pressure. heat or
Normally. the initial leak tends to be
decreased with a certain time (from some
minutes to some days depending on the
existing conditions) because the clearance
•
strain. or inclusion of fine foreign substances will turn to an ideal profile because of the
in the liquid under service conditions. And. interactive friction of the sliding surface
this is true even when machining of each ring (running in).
is finished precisely. As the result, a little leak
may exist during the initial operation. that is
so-called an initial leak.
Water
Hot water:
N
N
3 cc/Hr (1 drop/min.)
3 cc/Hr (1 drop/min.)
Continuous dripping
00.
Do.
c. Gear Coupling
c- 1 Construction
Fig. 3
Part No.
1
2
3
Table 9
Sleeve A
Part Name
Solid flange
Hub
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4 Reamer bolt
5 Class 1 nut
6 Side cover
7 Hexagon head cap screw
8 a-ring
9 a-ring
la a-ring
11 Oil plug
12 Grease nipple
10
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• CENTRIFUGAL PUMPS
•
c-2 Assembling Sequence Fig. 5
(1) Cleaning View@ View@
Clean the inner and outer cylinders A.
C2
thoroughly.
(2) Insertion of O-ring
Insert O-ring in the seal groove on the
side cover.
(3) Insertion of Inner and Outer Cylinders .".
Cl
in the Shaft
Put the side cover in the shaft, and (7) Assembling of Outer Cylinder
then after checking the direction of
Tighten the outer cylinder A and the
inner cylinder, fit it in the shaft. At
flange of solid flange by means of
this time, use care not to impair the 0-
ring. reamer bolt.
(4) Drive-in of Key In this case, be careful not to forget to
insert O-ring in the flange face. After
Oil can leak from the key on the part this work, install the side cover.
chamfered. So. apply key sealant fully
•
before driving it in. Fig, 6
(5) Mounting of Motor -L _
Mount the motor to put it in place.
(6) Centering
Mount a dial gage on one inner
cylinder, and put the measuring needle
on the reference face for centering.
Then, turn the shaft on the side where
a dial gage is installed carefully to
(8) Greasing
take reading of its run-outs.
(For centering, recommended run-outs Apply grease on the tooth faces of
inner and outer cylinders thoroughly
are as shown in the following table.)
before assembling, and grease up to
Fig. 4 the specified level from the grease
port.
_OH
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1'----~
(See Table-4)
I >liThe above greasing is critical for the
•
performance of gear coupling,
Because grease is to form an 011 film
on the gear contact face, which is
effective in prevention of the metal
surfaces from contacting each other
and thereby the wear resistance of
gear tooth is improved, as well as
noise and temperature rise and aiso
Table 10
Recommended Run-outs in Cantering some extent of self,excited vibration
Unit [mm] are prevented.
In this way, grease has a very
Parallel Axial
Angle Deviation important function, so that a proper
Model Deviation Clearance
(0) 8' C2-Cl (C) type grease must be used, (See p6)
(Grease may be deteriorated
N8E-103 0.04 0.05' 0.04 8
depending on the service conditions,
-1 15 0.04 0.05' 0,05 8 and therefore it should be replaced at
-125 0.05 0.05' 0.06 8 appropriate intervals, which makes the
life of coupling extended.)
-137 0.05 0.05' 0.06 8
•
-160(8) 0.06 0.05' 0.08 10
-175 0.06 0.05' 0.09 10
-190 0.06 0.05' 0.10 10
-224 0.07 0.05' 0.12 12
11
• CENTRIFUGAL PUMPS
d. Combining of Pump with Motor for Semi-
open Type Impeller
For: TMS-40A. 50B(4P), 65B(4P). 80B
(1 ) Pull out the pump shaft into the motor
side, and take measurement of A by
means of depth gage.
adjust it to be A+0.6 to 0.7 mm.
Then, fix it with a hexagon head cap
screw securely. (At this time, the
•
(2) Check the movement value by pushing clearance between the back of impeller
the motor shaft into the fan cover. and the casing cover should be 0.6 to
(Generally. it ranges from 1.0 to 1.5 0.7 mm.)
mm.) [Notellf this setting is failed, the back of
impeller and casing cover will come in
(3) After mounting the rigid coupling on the
contact with each other, which can be
motor shaft, take measurement of the cause of Qverload.
distance between the flange face of
motor and the end of coupling, where it (4) Combine the pump with the motor, After
is pushed toward the fan cover fully, and combining, check if they can turn
Fig. 7
,----
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, 'k
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,
A+O.S-O.7mm
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•
- f--- :-It
III
K- -
'-- o I'
,
\ , I---
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•
Fig. 8
•
12
• CENTRIFUGAL PUMPS
f. Separation and connection of models using
•
Fig. 9
friction joint For: EMD, 2p (3600rpm). EMS I
f- 1 Separation Coupling
(1) Move the coupling set jig to under the
Friction joint
friction coupling in order to prevent the Coupling set jig Coupling set jig
drop of the rotation part.(Refer to Fig.9)
(2) Rotate the Pressure screw
counterclockwise.(Ioosening)(Refer to
Fig.11) Mach. cover
Release the connection of the shaft
coupling and the shaft, and take the
motor off.
[Note] When rotating tje mentioned. perform it
until that end face touches the
setscrew.
Fig. 10 Rotor unit
f-2 Connection
Coupling set jig
(1) Clean and degrease the surface of the
friction joint. the shaft. and the hub that "'-.~~
•
is coupled by using fabric.
(2) Insert the friction joint on to the pump
shaft and fix them with C-type retaining
ring.
(3) Insert the rotor unit into the
casing.(Refer to Fig. 10)
At this time, be sure to move the
coupling set jig to under the friction
joint.
By doing this. rotation parts can be
installed on the proper position.
(4) Instail the coupling at the motor shaft-
end. and connect the pump and the
motor.
Fig. 11 Friction joint
(5) Rotate the pressure screw of the friction
joint to clockwise (tightening), and Pressure medium Sleeve
connect the coupling and the staft.
(Refer to Fig. 11 ) After the connection.
Stopper
•
against shaft and coupling and rigidly joint them.
Dismantling is done by loosing the pressurizing
screw that allows sleeve to back original dimension.
13
1O. Troubles and Remedies
Should troubles occur, their causes must be traced and necessary remedies must be resorted to.
As kinds of troubles the following can be conceivable: •
Table 11
Troubles Causes Remedies
Pump does not start. Motor out of operation. Repair motor.
Pump is seized. Repair pump.
No power source. Check up eiectric system.
Wiring is broken, or relay, etc. are in trouble. Repair.
Lack in voltage. Check UP electric system.
Pump starts. but Pump is not primed or insufficiently primed. Prime pump once more.
does not discharge Valves are not open. Open valves.
water. Valves cannot be opened. Repair valves.
Pump is sucking air. Check up suction systam and claan up inside.
Suction pipe or strainer is clogged. Clean suction pipe or strainer.
Impeller is clogged. Clean impeller.
Vacuum pump out of operation. Repair vacuum pump.
Motor rotating direction is wrong. Change wiring.
Pump starts, but Pump is sucking air. Check up suction system.
specified discharge Pump revolutions are too low. Correct electric source.
head is not reached. Discharge pressure is too high. Check up discharge piping.
Suction pipe or strainer is ciogged. Clean suction pipe or strainer.
Impeller is clogged. Clean impeller.
•
Worn casing ring. Renew casing ring,
Cavitation exists. Throttle valve on discharge side.
Gauges not in function. Replace gauges by new ones.
Impeller is worn. Replace impeller by new one.
Pump starts and Priming is insufficient. Prime pump.
discharges water, Air pockets exist in suction line. Correct piping.
but soon ceases to Pump is sucking air. Check up suction system.
discharge water. Pump is sucking air through stuffing box. Check up sealing pipe, adjust mechanical
seal and adjust gland packing.
Pump starts, but Abnormal contact exists in interior of pump. Remove contact.
motor gets Connection is wrong. Check up alignment.
overioaded. Packing is too tight. Loosen gland or renew packing.
Pump shaft is bent. Renew shaft.
Pump casing is deformed. Amend pump foundation base and piping.
Pump discharge is too mUCh. Throttle valve on discharge side.
Pump bearings are wrong. Renew pump bearings.
Pump starts, but Lubricant is in shortage. Supply lubricant.
bearings get Lubricant is too mUCh. Draw out lubricant.
overheated. Lubricant is unsuitable or incorrect. Replace lubricant by specified one.
Connection is wrong. Check up alignment.
Bearings are wrong. Renew bearings.
Shaft is bent. Renew shaft.
Thrust has increased. Check up whether one-sided wear exists or
•
impeller balance holes are clogged, and
reassemble if necessary.
Impeller balance is wrong. Repair or renew impeller.
Bearing assembly is wrong. Readjust bearings.
Pump starts, but Connection is wrong. Check up alignment.
vibration occurs. shaft is bent. Renew shaft.
Installation is wrong. Correct instaliatin condition.
Pump foundation is weak. Reinforce pump foundation base.
Other vibration is transmitted. Reinforce piping.
Cavitation exists. Throttle valve on discharge side.
Bearings are worn. Renew ball bearing or submerged bearing.
Impelier balance is wrong. Repair or renew impeller.
In case troubles cannot be remedied In accordance With the above table, the causes may be In the design
conditions of the pump. so it is preferable to consult the shlpyard or manufacturer.
.Head Office & 209-1 Shimotabuse, Tabuse-cho, Kumage·gun, Yamaguchi pref. 742-1598 Japan ,/"'""',,~
Factory TEL: 81-820·52·3113-4 FAX: 81·820·53-1 DD 1 E-mail:. business@taiko·kk.com .{_....U<:::;;
•
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TEL: 81·3·3221·8551 FAX: 81·3·3221-8555 E-mail: tokyo·br@taiko·kk.com
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