SAMES KREMLIN 40/1 - 750cc std User manual

INSTRUCTION MANUAL

HP CIRCULATING PUMP

& FLUID SECTION, model 4 BALLS

(stroke 200 mm / 8")

Version Pump # Fluid section #

40/1 - 750 cc std # 49 224 134 xx xx # 104 134 xx xx

53/1 - 570 cc std # 49 224 135 xx xx # 104 135 xx xx

53/1 - 570 cc st steel # 49 225 743 # 105 743

Manual : 574.275.112 – 1806

Date : 25/06/18 - Supersede : 25/06/12

Modif.: Update

KREMLIN REXSON



SAMES KREMLIN

TRANSLATION FROM THE ORIGINAL MANUAL

IMPORTANT : Before assembly and start-up, please read and clearly understand all the

documents relating to this equipment (professional use only).

THE PICTURES AND DRAWINGS ARE NON CONTRACTUAL. WE RESERVE THE RIGHT TO MAKE CHANGES WITHOUT PRIOR NOTICE.

SAMES KREMLIN SAS

13, chemin de Malacher

38 240 - MEYLAN - France



: 33 (0)4 76 41 60 60

www.sames-kremlin.com

SAMES KREMLIN 1 Manual : 574.275.112

INSTRUCTION MANUAL

HP CIRCULATING PUMP

& FLUID SECTION, model 4 BALLS

(stroke 200 mm / 8")

TABLE OF CONTENTS

1. WARRANTY .......................................................................................................................................................2

2. SAFETY INSTRUCTIONS..................................................................................................................................2

3. INSTALLATION..................................................................................................................................................6

4. OPERATING.......................................................................................................................................................7

5. USE.....................................................................................................................................................................8

6. MAINTENANCE................................................................................................................................................11

7. DISASSEMBLY / ASSEMBLY.........................................................................................................................12

8. CODIFICATION OF THE PUMPS....................................................................................................................15

9. SPECIFICATIONS............................................................................................................................................15

10. EXPLODED VIEW AND PARTS' LIST ............................................................................................................18

Dear Customer,

You are the owner of our new equipment and we would like to take this opportunity to thank you.

To make sure your investment will provide full satisfaction, special care has been taken by SAMES KREMLIN

during all designing and manufacturing processes.

To obtain the best result, safe and efficient operation of your equipment, we advice you to read and make

yourself familiar with instructions and service manual. Indeed, the non-compliance with instructions and

precautions stated in this manual, could reduce the equipment working life, result in operating trouble and

create unsafe conditions.

SAMES KREMLIN 2 Manual : 574.275.112

1. WARRANTY

We reserve the right to make changes; these changes may be carried out after the receipt of our order. No

claim will be accepted as a consequence of any change carried out in the instruction manuals or in the

selection guides.

Our equipment is checked and tested prior to shipment. In the case of a problem arising with the equipment,

this must be in writing, within ten days from the delivery date.

SAMES KREMLIN warrants all equipment manufactured bearing its name, to be free from defect in material

or workmanship for a period of 12 months (one shift per day or 1800 hours - 1 term reached) from the date of

delivery. Work life is based on single shift working - 8 hours per day. Warranty claims for defective items will

only be accepted in writing and will be verified and confirmed by us.

The warranty does not cover fair wear tear, damage or wear caused by misuse, improper maintenance or

non-observance of our recommendations.

SAMES KREMLIN will repair or replace parts (carriage paid to our plant and accepted as defective by us).

We shall not be liable for any losses, resulting from a production breakdown. Upon request, we can carry out

service work at your premises; all expenses (travelling and accommodation) for SAMES KREMLIN

technicians will be chargeable.

In the event that it is found that equipment has been tampered with, this will invalidate the warranty.

Equipment that is bought in will be subject to the supplier's warranty.

2. SAFETY INSTRUCTIONS

GENERAL SAFETY INSTRUCTIONS

CAUTION : The equipment can be dangerous if you do not use it according to

the rules mentioned in this instruction manual. Read carefully all the

instructions hereafter before operating your equipment.

Only trained operators can use the equipment.

The foreman must ensure that the operator has perfectly taken in the safety instructions of this equipment as

well as the instructions in the manuals of the different parts and accessories.

Read carefully all instruction manuals, label markings before operating the equipment.

Incorrect use may result in injury. This equipment is for professional use only. It must be used only for what it

has been designed for.

Guards (air motor cover, coupling shields, housings,…) have been designed for a safe

use of the equipment.

The manufacturer will not be held responsible for bodily injury or failure and / or

damage to property due to removal or partial removal of the guards.

Never modify the equipment. The parts and accessories supplied must be regularly inspected. Defective or

worn parts must be replaced.

Never exceed the equipment components' maximum working pressure.

Comply with regulations concerning safety, fire risks, electricity in force in the country of final destination of

the material. Use only products or solvent compatible with the parts in contact with the material (refer to data

sheet of the material manufacturer).

SAMES KREMLIN 3 Manual : 574.275.112

PICTOGRAMS

ADFECG

NIP HAZARD WARNING

MOVING

ELEVATOR

WARNING

MOVING PARTS

WARNING

MOVING

SHOVEL

DO NOT

EXCEED THIS

PRESSURE

HIGH PRESSURE

HAZARD

HJLKMQ

RELIEF OR

DRAIN VALVE

WARNING HOSE

UNDER

PRESSURE

WEAR GLASSES

OBLIGATORY

WEAR OF

GLOVES IS

OBLIGATORY

PRODUCT

VAPOR

HAZARDS

WARNING HOT

PARTS OR AREAS

NPR

ELECTRICAL

HAZARD WARNING FIRE

HAZARDS EXPLOSION

HAZARDS GROUNDING WARNING

(USER)

WARNING

SERIOUS

INJURIES

PRESSURE HAZARDS

Current legislation requires that an air relief shut off valve is mounted on the supply circuit of

the pump motor to let air off when closing the supply circuit. Without this precaution, the

motor residual air of the motor may let the pump beat and cause a serious injury.

Please ensure that, a material drain valve is mounted on the material circuit to drain it (after

shutting down air to the motor and the pressure relief) before any servicing on the

equipment. These valves must be closed for air and opened for product when processing.

HIGH PRESSURE INJECTION HAZARDS

When working with high pressure equipment, special care is required. Fluid leaks can occur.

Then there are injection risks in exposed parts of body that may cause severe injuries or

amputations :

Medical care must be handled immediately if product is injected under the skin or in

other parts of the body (eyes, fingers).

Never point the spray gun at any one. Never try to stop the spray with your hands or

fingers nor with rags or similars.

Follow the shut down procedure and always depressurize air and fluid circuits

before carrying out any servicing on the gun (cleaning, checking, maintenance of the

material or cleaning of the gun nozzles).

For the guns equipped with a safety device, always lock the trigger when you do not

start the gun.

SAMES KREMLIN 4 Manual : 574.275.112

FIRE - EXPLOSION - SPARKS - STATIC ELECTRICITY HAZARDS

A poor earth connection, inadequate ventilation, sparks or static electricity can cause an

explosion or fire. to avoid these risks when using or servicing SAMES KREMLIN equipment,

the following safety procedures must be followed :

ensure a good earth connection and ground the parts to be handled i.e. solvents,

materials, components and equipment,

ensure adequate ventilation,

keep working area clean and free from waste solvents, chemicals, or solid waste i.e.

rags, paper and empty chemicals drums,

never use electrical switches / power if in an atmosphere of volatile solvent vapour,

stop working immediately in case of electrical arcs,

never store chemicals and solvents in the working area.

TOXIC PRODUCT HAZARDS

Toxic products or vapours can cause severe injury not only though contact with the body, but

also if the products are ingested or inhaled. It is imperative :

to know the material products and their risks,

notified or hazardous materials must be stored in accordance with the regulations,

the material must be stored in an appropriate container, never place materials in a

container where there is a risk o spillage or leakage,

a procedure must be applied for the safe disposal of waste material. It must comply

with all prevailing regulations and legislations of the country where the equipment is to

be used,

protective clothing should always be worn in compliance with the material

manufacturers' recommendations,

depending on the application and chemical safety instructions, safety glasses, hearing

protective earplug, gloves, foot wear, protective masks and possible breathing

equipment should be worn to comply with the regulations

(Refer to chapter "Safety equipment of SAMES KREMLIN selection guide).

CAUTION!

It is forbidden using any solvent or with halogenated hydrocarbon base and also products

with these solvents facing aluminium or zinc. The non-compliance with the instructions may

cause explosion hazards causing serious or fatal injuries.

SAMES KREMLIN 5 Manual : 574.275.112

EQUIPMENT REQUIREMENTS

Guards (air motor cover, coupling shields, housings,…) have been designed for a

safe use of the equipment.

The manufacturer will not be held responsible for bodily injury or failure and / or

damage to property due to removal or partial removal of the guards.

PUMP

Before carrying out any work, it is imperative to get used with the compatibilities of motors with

pumps before coupling. The operator shall understand the equipment and the safety

instructions. These instructions are available in the manuals of the pumps.

The air motor is designed to be mounted with a pump. Never modify any components or

couplings. Where operating, please keep hands away from moving parts. Before starting up the

equipment, please read the PRESSURE RELIEF instructions. Please ensure that any relief or

drain valves fitted are in good working order.

HOSES

Keep hoses out of circulation areas, moving parts or hot surfaces,

Never expose product hoses to temperature higher than + 60°C / 140° F or lower than

0°C / 32° F,

Never pull or use the hoses to move the equipment,

Tighten all fittings as well as the hoses before operating the equipment,

Check the hoses regularly; change them if they are damaged,

Never exceed the maximum working pressure (MWP) indicated on the hose.

USED PRODUCTS

Considering the variety of products that may be used by the users and the impossibility to

check off all chemical data, of possible reactions of chemicals to each other and their long term

evolution, SAMES KREMLIN can not be considered as liable for :

the bad compatibility of wetted parts,

risks for staff and surroundings,

for worn or out of order parts, for wrong working of equipments or units, as well as for the

qualities of final product.

The user must know and prevent the possible risks as toxic vapours, fires or explosions due to

used products. He shall determine the risks of immediate reactions or pursuant to repeated

exposures of the staff.

SAMES KREMLIN shall not be liable for psychic injuries, direct or indirect material damages

further to the use of chemicals.

SAMES KREMLIN 6 Manual : 574.275.112

3. INSTALLATION

HANDLING

The pumps and the fluid sections with important weight and dimensions must be handled with the

appropriate means.

STORAGE

Place the equipment safe from dampness after having closed the different air inlets and ports (plugs).

DESCRIPTION OF THE LABEL MARKING

Marking in

accordance

with the

ATEX

directive

SAMES KREMLIN

STAINS FRANCE Name and address of the manufacturer

MOTEUR /MOTOR -

POMPE / PUMP Fluid section part number and serial number. The two first numbers indicate

the manufacturing year.

MOTO-POMPE / MOTOR-PUMP Pump part number and serial number. The two first numbers indicate the

manufacturing year.

II 2 G CE CE : European conformity :For use in explosive area

II : group II 2: class 2 G: gas

Surface equipment meant to an area where explosive atmospheres due to

gas, vapours, mists are liable to appear from time to time in usual operating.

Associated to a pneumatic motor, the fluid sections must be grounded via

the earth cable of that motor.

The earth cable must be grounded to a safe earth.

The pumps are designed to be installed in a spray booth.

CONNECTION OF THE SUBSETS

These fluid sections are designed for the coupling of pneumatic or hydraulic motors with similar stroke.

You must conform to a motor / fluid section association as planned by SAMES KREMLIN.

SAMES KREMLIN 7 Manual : 574.275.112

4. OPERATING

EXPECTED USE

These pumps are designed for the transfer, the pouring off or the spraying of different liquid or viscous

fluids with a requested outlet flow and pressure.

OPERATING DESCRIPTION

DOUBLE EFFECT pump : suction and exhaust are carried out in the 2 translations stages.

A - The piston goes

down

= suction + exhaust

The piston goes

down. The B1 ball

lifts itself up : the V1

chamber is filled. The

V2 exhaust pressure

presses the B2 ball

on its seat and forces

the opening of the B4

ball and forces the

B3 ball on its seat.

There is exhaust

and pressure

increasing

B- The piston goes up

= suction + exhaust

The piston goes up, the

B2 ball lifts itself

up. The V2 chamber is

filled. The V1 exhaust

pressure presses the

B1 ball on its seat,

forces the opening of

the B3 ball and presses

the B4 ball on its seat.

There is exhaust and

pressure increasing..

WARNING!

The frictions due to the displacement of fluid inside the pumps and accessories, as

well as the one created by the tightness seals, generate static electricity that may

cause fire or explosion. This is why the pump must be grounded (refer to the

instruction manual of the motor for its grounding).

Never place hands on the suction port of the pump. The suction power can

lead to serious injuries.

SAMES KREMLIN 8 Manual : 574.275.112

5. USE

Protective clothing (gloves, protective masks, glasses, hearing

protective earplug, protective clothing…) should be worn to

comply with the recommendations.

The working area must be correctly ventilated.

Guards (air motor cover, coupling shields, housings,…) have been designed for a safe

use of the equipment.

The manufacturer will not be held responsible for bodily injury or failure and / or

damage to property due to removal or partial removal of the guards.

ADJUSTMENTS

Before starting the equipment, half fill the cup as well as the 2 tanks with T lubricant.

The cup nut must be slightly tightened. A too important tightening would damage the cup seals. A

wrench is supplied to allow a correct tightening.

Tightening of the cup :

- Fill the cup with T lubricant,

- Start the pump, then tighten the cup after 10 minutes, then one hour and then one day of operating,

- If you notice a leakage, the cup must be tightened.

Tightening instructions :

- Depressurize the motor (refer to pressure relief instructions),

- Depressurize the fluid circuit (refer to pressure relief instructions),

- Tighten the cup, clean it and fill it with T lubricant,

- Close the pump drain circuits,

- Open the motor air valve.

START UP

Guards (air motor cover, coupling shields, housings,…) have been designed for a safe

use of the equipment.

The manufacturer will not be held responsible for bodily injury or failure and / or

damage to property due to removal or partial removal of the guards.

The pumps are tested in our workshop with lubricant.

Before starting up, you must flush the pump with the appropriate solvent.

At the end of the working day, carry out a flushing with the appropriate solvent. We advice you to stop

the fluid section in the "low position" to prevent material spreading on the piston rod.

SAMES KREMLIN 9 Manual : 574.275.112

TROUBLESHOOTING

Before any intervention on the pump, please carry out the release pressure and

drain general instructions.

Guards (air motor cover, coupling shields, housings,…) have been designed for a safe

use of the equipment.

The manufacturer will not be held responsible for bodily injury or failure and / or

damage to property due to removal or partial removal of the guards.

To prevent from injuries, material injections, injuries due to moving parts or sparks during the stopping of the

system, the assembly, the cleaning or changing of the nozzle, you must follow the stages hereafter before

intervening :

- Close the guns,

- Shut off the air inlet using the pressure release to evacuate the residual air.

- Move the gun near to a metallic drum to get back the fluid. Keep it against the drum to maintain

the grounding (if necessary use a wire to ground the metallic drum).

- Open the gun to drain the circuit.

- Open the drain valve of the pump and get back the fluid in a metallic drum correctly grounded.

- Let the drain valve open during the intervention.

Check the conformity of cabling before intervening.

DEFECTS CAUSES SOLUTIONS

Leakage at the cup seals

Insufficient tightening of the cup. Screw the cup.

Bad mounting of the seals Check the mounting

Damaged or worn seals. Replace them.

Bad choice of the seals' material Check the compatibility.

The cup seals get rapidly damaged No lubricant in the cup (pumped

product drying on the piston rod).

Clean, replace parts if necessary.

During a long duration shutdown,

stop the pump, the piston is in the

the low position.

Compatibility product / seals. Check.

The pump is stopped

The fluid is polymerized, hardened,

dried in the pump. Clean the pump; change parts if

necessary.

The cup nut is too tightened. Unscrew.

Broken part(s) in the pump. Remove, check and replace.

The motor seems to operate but

the pump does not deliver product

Internal parts of the motor

defective. Check the operating of the motor.

Defective coupling. Check coupling.

The pump operates but irregular

flow

Valve clogged on the seat,

incorrectly mounted or worn. Check mounting, state of the parts,

tightening of parts and seals.

Air inlet in the suction circuit.

This manual suits for next models

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