SAMES KREMLIN AZUR 72C160 Manual Download

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Maintenance

Twice a month

If the lubricant is strongly colored in the cup, renew it.

Check that the cup remains clean and clean it regularly
with solvent after draining the lubricant.

Once a month

Check that the air regulator and pressure gauge are working properly.

Every year

Disassemble the fluid section fully.

Clean all parts. Fit new seals when reassembling the
pump (see replacement seal kit).

Put grease on the piston and inside the cylinder, to avoid
damaging the seals.

Fit new parts if necessary.

Summary of Contents for AZUR 72C160

Page 1: ...60131101 64350160131111 64350160135111 64350160131175 64350160131115 64350160134115 User Manual 582109110 2023 09 08 Index I Translation of the original instructions SAMES KREMLIN SAS 13 Chemin de Mal...

Page 2: ...y form whatsoever and any exploitation or communication of its contents is prohibited except with the express written consent of SAMES KREMLIN The descriptions and features contained in this document...

Page 3: ...2 TABLE OF AZUR AIRLESS PUMP AND PACKAGE CODES 21 3 1 3 VISUALS OF THE PROPOSED CONFIGURATION 22 Context of use 23 3 2 DESCRIPTION OF THE MAIN ELEMENTS OF THE SYSTEM 24 Pump 72C160 24 Motor 146371000...

Page 4: ...ection part 60 Motor part 62 11 2 PREVENTIVE MAINTENANCE 63 12 DISASSEMBLY REASSEMBLY OPERATION 64 12 1 DISASSEMBLY 64 Disassembly of the grounding cable 64 Preliminary operations 65 12 2 DISCONNECT T...

Page 5: ...kit 144 050 403 215 Fluid section seal kit 144 050 404 216 Fluid section seal kit 144 050 405 217 17 3 SPARE PARTS PRODUCT FILTER 3 4 MODEL 500 BAR 7252 PSI 218 Option 220 Accessories 222 Hoses codifi...

Page 6: ...30 2020 Week 32 2020 N Plantard E DUMONT F SEGUIN AIRLESS pump F Week 38 2020 N Plantard F SEGUIN AIRLESS pump G Week 38 2020 N Plantard F SEGUIN AIRLESS pump H Week 04 2023 N Plantard F SEGUIN AIRLES...

Page 7: ...rranty excludes wear parts deterioration or wear resulting from abnormal or unscheduled use by SAMES KREMLIN failure to observe instructions for proper operation or lack of maintenance The warranty is...

Page 8: ...cause serious injury This material is for professional use only It must be used only for the purpose for which it was intended Do not modify or transform the material Parts and accessories must only b...

Page 9: ...ion Danger hot parts or surfaces Danger flammability risks Danger electricity Risk of explosion Danger user Warning Danger Gloves required Grounding Protective helmet Hearing pro tection Mandatory res...

Page 10: ...equipment components Danger of Pressure Safety requires that a decompressed air shutoff valve be mounted on the pump motor supply circuit to allow trapped air to escape when the supply is shut off Wi...

Page 11: ...nding insufficient ventilation open flames or sparks can cause an explosion or fire which could result in serious injury To avoid these risks especially when using pumps it is imperative To connect th...

Page 12: ...plication in a container designed for that purpose Evacuate the products in accordance with the legislation of the country where the equipment is used To wear protective clothing designed for that pur...

Page 13: ...ut in place for safe use of the equipment Exemples Engine hood Carters The manufacturer can not be held responsible in case of Bodily injury As well as breakdowns and or damage to the equipment result...

Page 14: ...MPRESSION PROCEDURE Check that the decompression and purge air valves are working properly It is forbidden to operate the pump without its protective motor cover risk of crushing It is forbidden to di...

Page 15: ...oves safety shoes Do not look at the gun nozzle when it is under pressure Rinse at a maximum of 1 bar at the pressure gauge of the air equipment variable pressure depending on the length of the pipes...

Page 16: ...and connectors before commissioning the equipment Check hoses regularly replace them if damaged Never exceed the maximum operating pressure stated on the hose PMS For fitting the hoses and gun PPE is...

Page 17: ...erent risks to staff and the environment Wear and tear maladjustment malfunction of equipment or machines and the quality of the finished product The user will have to identify and prevent the potenti...

Page 18: ...ations moving equipment etc where damage to the grounding function is likely the user will have to replace the wire of 2 5 mm supplied by a device more adapted to its environment wire of greater secti...

Page 19: ...the device important information for the use of the device pressure power and sometimes against the pictogram shown below The equipment is designed and manufactured with high quality materials and com...

Page 20: ...Presentation of the material 20 3 Presentation of the material 3 1 Complete system 3 1 1 Generic presentation visual Ind Descrption A Azur Pump B Gun C Hose D Suction rod E Bucket F Filter G Cart...

Page 21: ...r TE Sflow gun Airless hose 15m 3 8 1 6m 1 4 Bare Wall mounted Cart Hose 600 mm Hose 1000 mm Gravity hopper 64350160130000 312 X 64350160131101 312 X X X 64350160131111 312 X X X 64350160135111 312 X...

Page 22: ...Azur Pump 72C160 64350160130000 Wall mounted Azur pump 72C160 Air supply Suction rod L600 64350160131101 Wall mounted Azur pump 72C160 Air supply Filter Suction rod L1000 64350160131111 Wall mounted...

Page 23: ...bly Valve Drain 64350160131175 Azur Pump 72C160 Air supply Cart Hopper Filter 64350160134115 Context of use AZUR AIRLESS 72C160 pumps are designed to meet the required performance and lifetime require...

Page 24: ...24 3 2 Description of the main elements of the system Pump 72C160 Expected use These pumps coupled with air motors are designed to transfer or spray different liquid or pasty products with a desired f...

Page 25: ...pected use This Pneumatic motor is intended to be coupled to the fluid section systems recommended by SAMES KREMLIN in order to obtain the ratio and the expected flow rate Functional description Doubl...

Page 26: ...pressure via the air regulator leads to an increase of the number of pump piston returns mn cycles which leads to a flow rate increase and to an outlet pressure increase of the pumped material AIR CO...

Page 27: ...Presentation of the material 27 1 3 2 Chamber rod assembly Switch set Carter distributor...

Page 28: ...packing Lower packing 144050412 PTFE LEATHER PTFE 4x PTFE 4x LEATHER 3x PTFE 3x LEATHER 144050413 UHMWPE PTFE PTFE 4x UHMWPE 4x LEATHER 3x UHMWPE 3x LEATHER 144050414 UHMWPE LEATHER PTFE 4x PTFE 4x L...

Page 29: ...rasive material preximed 2K material Perfect for intensive use 144050403 UHMWPE PTFE Good chemical compatibility Ideal for preximed 2K material Not ideal for abrasive material 144050404 UHMWPE Leather...

Page 30: ...king Principles Paint pumps are designed to be installed in a paint booth This equipment complies with the following provisions ATEX Directive 2014 34 EU II 2 G Group II Category 2 Gas This UE Declara...

Page 31: ...gas for equipment qualification T2 T4 Temperature class Maximum surface temperature Gb Gb Equipment protection level Gas zone1 X X Special conditions apply for safe use Refer to the requirements in t...

Page 32: ...avy duty cart 0225 Pump Output 0160 Fluid section material 0 None 1 with filter SST Inox 1 2 with filter SST 2 outputs Seal pack 7 with priming kit PTFE Leather 2 UHMWPE PTFE 3 Pump control panel UHMW...

Page 33: ...4 NPSM 2 1 6m Polyamid 1 4 1 4 NPSM PTFE Leather 2 Main hose lenght UHMWPE PTFE 3 UHMWPE Leather 4 UHMWPE PTFE G 5 0 None Pump input 10 10m Polyamid 3 8 3 8 NPSM 15 15 m Polyamid 3 8 3 8 NPSM None 0...

Page 34: ...Equipment plans 34 6 Equipment plans Pump 72C160...

Page 35: ...Equipment plans 35 Wall mounted pump...

Page 36: ...Equipment plans 36 Pump 72C160 Cart...

Page 37: ...Equipment plans 37 Pump 72C160 Cart Hopper...

Page 38: ...Equipment plans 38 Fluid section C160...

Page 39: ...Equipment plans 39 Motor 7000 Stroke 120...

Page 40: ...Equipment plans 40 Air supply...

Page 41: ...Equipment plans 41 Filter...

Page 42: ...Equipment plans 42 Pump priming kit...

Page 43: ...Equipment plans 43 Hopper...

Page 44: ...pply without filter 60 4 kg 133 2 lbs Wall mounted Suction rod air supply filter 64 2 kg 141 5 lbs Cart Suction rod air supply filter 80 3 kg 177 lbs Cart hooper air supply filte 84 1 kg 185 4 lbs The...

Page 45: ...Technical specifications and operating principles 45 MOTOR 7000 STROKE 120 146371000 Motor type 7000 120 Motor stroke 120 mm Motor section 484 cm Weight 35 kgs 77 17 lbs...

Page 46: ...ion C160 67 5 cm Volume of product delivered per cycle 160 cc Number of cycles per liter of product 6 25 Flow rate at 20 cycles 3 2 C160 Sealing gasket Fixed end 8 chevron seals 4 UHMWPE 4 PTFE or 4 P...

Page 47: ...ctional description When the piston 1 rises the Upper 2 closes or Lower Ball check 3 opens The piston 1 expels the product from the upper chamber V2 to the outside and sucks the product to fill the lo...

Page 48: ...cable see motor instructions for grounding Never place your hand on the suction port of the pump The suction power may cause serious injury Motor operation description SAMES KREMLIN pneumatic motors w...

Page 49: ...ES KREMLIN Grounding Coupled with a pneumatic motor the fluid section will be grounded via the earth cable of this motor This ground cable must be connected to a safe ground Loosen the lock nut A remo...

Page 50: ...tive to install a decompression valve after the air regulator and as close as possible to the engine inlet in order to follow the decompression procedure See the pump manual Operating problems The eng...

Page 51: ...orage before installation Storage ambient temperature 0 C 50 C 32 F 122 F Protect the unit against dust water runoff moisture and shocks Storage after installation Protect the unit against dust water...

Page 52: ...the end of the day rinse with a suitable solvent It is advisable to stop the fluid section in the low inversion position in order to prevent the product from catching on the piston rod Motor Engines...

Page 53: ...l Start pressure about 500 grams 10 2Safety in production Guards motor cover coupling guard housings are set up for safe use of the equipment The manufacturer can not be held responsible in case of bo...

Page 54: ...higher pressure never stay on this zone while operation up to 0 3Br Long operation on this zone will generate material leakage on the cup lub Vert Long operation on this zone will generate material l...

Page 55: ...ing the continuity of the earthing use the wire with stirrup to put the metal bucket to earth Open the gun valve tap to bleed the circuit Lock the gun valve tap to OFF Open the pump bleed valve and co...

Page 56: ...siccant filter to lower the water vapor content of the air Raise the compressed air temperature Warmer air going in helps the motor parts stay above 0 c 32 F Compressed air especially at these volumes...

Page 57: ...tibility seals Check The pump is stopped The product is cured dried in the pump Clean the fluid section change the parts if necessary Breakage of part s in the pump Disassemble check replace The engin...

Page 58: ...installation of damaged seals or seals Check the assembly change if necessary The pump does not deliver enough pressure Insufficient engine air pressure insufficiently open valve air leak Check adjust...

Page 59: ...ston lock Defective switch Adjust or replace the switch es Defective control distributor Check operation replace if necessary Defective power distributor Check operation replace if necessary Decrease...

Page 60: ...p the pump when the piston is in the down position Fluid section part Daily Detect leaks at connections Check the condition of the hoses Clean the piston of the pumps Do not let the product dry on it...

Page 61: ...lvent after draining the lubricant Once a month Check that the air regulator and pressure gauge are working properly Every year Disassemble the fluid section fully Clean all parts Fit new seals when r...

Page 62: ...hoses rubber crimping regulators and manometers The tightening of the components The condition of the muffler s The fixing of the hood The correct operation of the safety valve The state of the decom...

Page 63: ...c grease Make sure that none of them get damaged cutting one of them may cause the engine to malfunction 11 2Preventive maintenance Fluid section It is recommended to schedule a routine maintenance af...

Page 64: ...vention it is imperative to follow the decompression procedure and the safety instructions 12 1Disassembly Disassembly of the grounding cable Hold the grounding terminal with a 10 mm spanner and unscr...

Page 65: ...reliminary operations Option If the pump is equipped with air equipment turn off the air supply with the valve 1 Unscrew the air supply hose 2 with a 32 mm spanner blocking the air inlet fitting 3 wit...

Page 66: ...Disassembly Reassembly Operation 66 Remove the 2 screws with a 6 mm BTR wrench and then the washers from the motor cover Tools needed 6...

Page 67: ...Disassembly Reassembly Operation 67 Remove the motor hood...

Page 68: ...Disassembly Reassembly Operation 68 If it is necessary to change the switches first remove the pneumatic hoses manually Note Locate hoses for reassembly...

Page 69: ...Operation 69 Remove the 4 screws with a 3 mm BTR wrench and then the washers 1 Manually remove the connectors 2 and switches 3 Remove the 2 screws 5 with a BTR wrench of 3 mm Manually remove the distr...

Page 70: ...embly Reassembly Operation 70 12 2Disconnect the motor and the fluid section Using a flat screwdriver disengage the axle brake 1 from the groove above the locking ring 2 in order to release it Tools n...

Page 71: ...Disassembly Reassembly Operation 71 Manually lift the locking ring 1 and manually remove the coupling nuts 2 underneath...

Page 72: ...sembly Operation 72 Using a 24 mm wrench unscrew the 4 nuts connecting the flange to the tie rods and remove the 4 washers Attention Support the fluid section well Fluid section weight 11 kg 24 25 lbs...

Page 73: ...Disassembly Reassembly Operation 73 Separate the motor from thefluid section and retrieve the closing ring...

Page 74: ...Disassembly Reassembly Operation 74 If the motor is mounted on a support unscrew the two nuts with a 27 mm wrench and remove the two washers from the handles under the lower flange Tools needed 27...

Page 75: ...Disassembly Reassembly Operation 75 If the engine hood has not been removed in the previous steps remove the engine hood with a BTR wrench of 6 mm by removing the two screws and washers Tools needed 6...

Page 76: ...Disassembly Reassembly Operation 76 Sling on the lifting ring bracket Tools needed...

Page 77: ...Disassembly Reassembly Operation 77 Place the engine on a horizontal plane using a bridge or a stem Tools needed...

Page 78: ...Disassembly Reassembly Operation 78 Retract the motor shaft manually...

Page 79: ...Disassembly Reassembly Operation 79 Remove the 4 tie rods with a 19 mm wrench Tools needed 19...

Page 80: ...ly Reassembly Operation 80 In the event of disassembly of the lower bearing change of seals unscrew the 4 screws with a BTR wrench of 5 mm Manually remove the lower bearing along the motor shaft Tools...

Page 81: ...Disassembly Reassembly Operation 81 Using a flat screwdriver replace the seals 1 and 2 Tools needed...

Page 82: ...y Reassembly Operation 82 Attention Manually maintain pressure on the sheet metal 1 before unscrewing the 4 screws Remove the 4 screws with a 6 mm BTR wrench and the washers from the housing grid Tool...

Page 83: ...Disassembly Reassembly Operation 83 Remove the crankcase and protective foam from the motor...

Page 84: ...Disassembly Reassembly Operation 84 Remove the pneumatic hoses from the distributor leaving the bulkheads...

Page 85: ...Disassembly Reassembly Operation 85 Remove the 4 rigid foams and their holders from the distributor...

Page 86: ...Disassembly Reassembly Operation 86 Remove the 4 screws above and below the housing using a BTR wrench of 4 mm Tools needed 4...

Page 87: ...Disassembly Reassembly Operation 87 Remove the 4 screws connecting the distributor to the housing using a BTR wrench of 6 mm Tools needed 6...

Page 88: ...Disassembly Reassembly Operation 88 Remove the two exhaust mounts...

Page 89: ...Disassembly Reassembly Operation 89 If necessary place the distributor assembly on a workbench for disassembly...

Page 90: ...Disassembly Reassembly Operation 90 To dismantle the distributor remove the 4 screws using a BTR wrench of 6 mm Seal A is sold with the distributor Tools needed 6...

Page 91: ...Disassembly Reassembly Operation 91 Disassembly of the safety valve requires a spanner of 20 mm Disassembly of the 2 7 4 pipe fittings requires a 10 mm spanner Tools needed 10 20...

Page 92: ...Disassembly Reassembly Operation 92 Remove the flat gaskets as well as the plastic sheet with the assembled bulkheads...

Page 93: ...Disassembly Reassembly Operation 93 A If necessary manually retract the motor rod to adjust its position A...

Page 94: ...Disassembly Reassembly Operation 94 To unscrew the cam hold the rod 1 with an 8 mm BTR wrench Unscrew the screw 3 with an 8 mm BTR wrench and manually remove the cam 4 Tools needed 8 x2...

Page 95: ...Disassembly Reassembly Operation 95 Using the slings approach the motor in a vertical position above a suitable vice Attention in vertical position the motor rod falls down by gravity Tools needed...

Page 96: ...ve the motor from the vice so that the lower flange rests on the jaws of the vice and the rod is locked in the jaws Attention If the vice does not have a soft jaw use a cloth to avoid damaging the rod...

Page 97: ...Disassembly Reassembly Operation 97 Remove the bracket with the switches and the 5 2 bistable distributor unscrewing the two screws at its base with a 10 mm open end wrench Tools needed 10...

Page 98: ...Disassembly Reassembly Operation 98 Attention it is strongly discouraged to remove the caliper the tightening torque required for its installation being very high...

Page 99: ...Disassembly Reassembly Operation 99 To change the seals disassemble the upper bearing by removing the 4 screws with a BTR key of 5 mm Tools needed 5...

Page 100: ...Disassembly Reassembly Operation 100 Using a flat screwdriver change the seals 1 and 2 Tools needed...

Page 101: ...m the motor holding the top nut 1 with a 19 mm socket wrench while removing the corresponding bottom nut and washer assembly 2 with the other wrench Attention be careful not to do the opposite operati...

Page 102: ...Disassembly Reassembly Operation 102 Remove the 4 rods from the motor Note Note the mounting direction of the flange before removing it Tools needed...

Page 103: ...Disassembly Reassembly Operation 103 Remove the top flange of the motor by locating its position Tools needed...

Page 104: ...Disassembly Reassembly Operation 104 To replace the seal 1 of the upper flange of the motor remove it manually using a flat screwdriver Tools needed...

Page 105: ...ssembly Reassembly Operation 105 Loosen the vice and remove the rod and motor piston assembly Note it is normal for the seal to float in the piston groove between the piston and the cylinder Tools nee...

Page 106: ...Disassembly Reassembly Operation 106 Retrieve the piston seal Tools needed...

Page 107: ...assembly Operation 107 To replace the stem seal first unscrew the 6 screws with a BTR key of 6 mm to remove the two upper and two lower flanges Note mark the mounting direction of the counter flanges...

Page 108: ...Disassembly Reassembly Operation 108 Remove the piston 1 and then remove the seal 2 using a flat screwdriver Tools needed...

Page 109: ...Disassembly Reassembly Operation 109 Manually remove the cylinder from the lower flange Tools needed...

Page 110: ...Disassembly Reassembly Operation 110 Remove the gasket from the lower flange using a flat screwdriver Tools needed...

Page 111: ...Disassembly Reassembly Operation 111 Attention never disassemble the plate of firm of the equipment present on the lower flange...

Page 112: ...TTENTION The procedure described below requires the use of a vice and a workbench Place seals 1 and 2 in their respective locations on the motor bearing Grease the entire joint contour evenly with ind...

Page 113: ...Operation 113 Place the engine bearing fitted with greased seals in each of the two flanges Screw the 4 screws connecting each bearing to the corresponding flange upper and lower using a BTR key of 5...

Page 114: ...Disassembly Reassembly Operation 114 Fit the gasket on the flange and lubricate evenly over the entire joint contour with the industrial grease Tools needed Kluber petamo HY 133N...

Page 115: ...ion 115 Place and insert with a mallet the motor cylinder on the lower flange The cylinder must come into abutment on the flange Grease the inside of the cylinder evenly over the entire contour Tools...

Page 116: ...ssembly Operation 116 Place the motor rod lower part in a V jaw vice protect this rod so as not to damage it Attention If the vice does not have a soft jaw use a cloth to avoid damaging the rod coatin...

Page 117: ...Disassembly Reassembly Operation 117 Place the seal on the motor rod Grease the seal Tools needed Kluber petamo HY 133N...

Page 118: ...Disassembly Reassembly Operation 118 Push the drive piston onto the motor rod 1 and place this piston between the two grooves 2 of the rod It must cover the seal Tools needed...

Page 119: ...em in the grooves 1 of the drive rod pay attention to the direction Screw and glue anaerobic adhesive low threadlock the 6 screws CHC M8X45 3 with a key BTR of 6 mm Wipe off excess glue Attention Atte...

Page 120: ...lace the floating seal in the groove of the motor piston Then lubricate it evenly over the entire contour Note It is normal for the seal to float in the piston groove between the piston and the cylind...

Page 121: ...Disassembly Reassembly Operation 121 Undo the vice lift and place the rod and piston assembly on a bench Tools needed...

Page 122: ...Disassembly Reassembly Operation 122 Place the lower flange and power cylinder assembly on the open vise by positioning the rod over the vise crosshead Tools needed...

Page 123: ...embly Reassembly Operation 123 Take up the rod and piston assembly with the lifting means through the lifting eye Evenly grease the entire height of the rod circumference Tools needed Kluber petamo HY...

Page 124: ...Disassembly Reassembly Operation 124 From above position the rod 1 in the bronze bearing 2 of the motor bearing and SLOWLY lower the rod piston assembly Tools needed...

Page 125: ...Disassembly Reassembly Operation 125 Gently bring the floating seal 1 of the rod and piston assembly into contact with the upper edge 2 of the cylinder Tools needed...

Page 126: ...Disassembly Reassembly Operation 126 Place the seal in the motor cylinder by guiding it manually along the entire contour of the cylinder Attention Risk of pinching Tools needed...

Page 127: ...Disassembly Reassembly Operation 127 Lower the rod and piston assembly to the stop on the lower flange of the motor or vice Tools needed...

Page 128: ...Disassembly Reassembly Operation 128 Place and fit with a mallet the upper flange equipped with stirrup until the stop Attention to the direction of assembly Tools needed...

Page 129: ...Disassembly Reassembly Operation 129 Place the 4 tie rods nut on the motor from above and on the lower part place the washers nut on the tie rods Tools needed...

Page 130: ...Disassembly Reassembly Operation 130 MANUALLY tighten the nuts 1 as far as they will go Tools needed...

Page 131: ...Disassembly Reassembly Operation 131 Tighten the cam 2 with the CHC M10 screw 1 with a BTR key of 8 mm and counterblock on the flat part of the rod with a BTR wrench of 8 mm Tools needed 8 x2...

Page 132: ...Reassembly Operation 132 In the case not recommended where the bracket has been removed reinstall the bracket with the 2 CHC M18 screws using a 14 mm BTR torque wrench with a torque of 260 N m Tools n...

Page 133: ...bly Reassembly Operation 133 In the case where the bracket has been dismounted reinstall it on the motor by fixing the two screws located at its base using a spanner or a pipe wrench of 10 mm Tools ne...

Page 134: ...Disassembly Reassembly Operation 134 Fix the two switch sensors 3 on the bracket by placing the washers and tightening the 4 screws 1 and the connections 2 with a BTR key of 3 mm Tools needed 3...

Page 135: ...Disassembly Reassembly Operation 135 Remove the motor unit on a horizontal plane established type using a lifting device hooked to the caliper Tools needed...

Page 136: ...Disassembly Reassembly Operation 136 Manually re enter the motor shaft...

Page 137: ...Disassembly Reassembly Operation 137 Install the tie rods using a 19 mm torque wrench with a tightening torque of 100 N m Pay attention to the tightening torque Tools needed 19...

Page 138: ...Disassembly Reassembly Operation 138 If the bulkheads are not mounted on the plastic sheet Screw all the partition passes and onto the plastic sheet...

Page 139: ...2 7 4 on the base with a 10 mm spanner Fit the 90 elbow on the base with a flat wrench of 13 mm and orient it according to the image below image Fit the on the 90 elbow with a 17 mm spanner Fit the s...

Page 140: ...g tube glue and screw the power supply with the elbow fitting with a 27 mm spanner Glue with glue the sealed tube and screw the assembly on the fitting Tighten with a 27 mm spanner using connection an...

Page 141: ...port rigid foam 2 Screw the 2 screws CHC M8 the previous subassembly on the exhaust support with a 6 mm BTR key x2 Repeat the previous two steps on the other side of the exhaust bracket 4 Follow the s...

Page 142: ...Disassembly Reassembly Operation 142 Place the 2 previous sub assemblies on the equipped base with the 4 screws CHC M8...

Page 143: ...te of the housing on the vise to facilitate the work of fixing the joints Place the two base seals between the plastic plate and the base Attention Be sure to grease the joints sufficiently to promote...

Page 144: ...Disassembly Reassembly Operation 144 Using a 4 mm BTR wrench attach the distributor assembly to the plastic sheet with the 4 screws Tools needed 4...

Page 145: ...sassembly Reassembly Operation 145 Place the two other base seals 1 on the outside of the plastic sheet of the housing by passing them in the screws 2 Grease the seals Tools needed Kluber petamo HY 13...

Page 146: ...ssembly Reassembly Operation 146 Move the assembly to the motor flanges and screw the 4 screws CHC M8 with a 6 mm BTR key Note Check the tightness so that there is no daylight at the seals Tools neede...

Page 147: ...Disassembly Reassembly Operation 147 Make the pneumatic wiring of the distributor part...

Page 148: ...Disassembly Reassembly Operation 148 Wall bracket option Screw both daggers with a 27 mm torque wrench with a tightening torque of 260 Nm on the lower flange Tools needed 27...

Page 149: ...Disassembly Reassembly Operation 149 Using a 19 mm torque wrench tighten the 4 nuts of the tie rods with a tightening torque of 100 N m Tools needed 19...

Page 150: ...assembly Operation 150 Place the foam and the grid by putting the 4 washers and the 4 screws CHC M8 with a key BTR of 6 mm Attention Manually maintain pressure on the plate 1 to tighten the 4 screws T...

Page 151: ...Disassembly Reassembly Operation 151 Make the pneumatic wiring of the upper part...

Page 152: ...Disassembly Reassembly Operation 152 Place the cover and washers by screwing in the CHC M8 screws with a 6 mm BTR wrench Tools needed 6...

Page 153: ...ly Reassembly Operation 153 Wall bracket option With lifting means Place the assembly on the support option and screw the 2 nuts washers 27 mm torque wrench with a tightening torque of 100 N m Tools n...

Page 154: ...Disassembly Reassembly Operation 154 Reinstall the grounding cable with a wrench of 10 mm Tools needed 10...

Page 155: ...he axle brake and the locking ring along the motor shaft Make the coupling of the motor to the fluid section Note It is important to perform this operation vertically Attention Support the fluid secti...

Page 156: ...crewing the 4 M16 nuts in contact Coupling to the fluid section Connecting the Air supply Run the pump slowly at no load for 3 cycles to align the pump seals vertically Tighten the four nuts in star w...

Page 157: ...13 Pneumatic Wiring Count cycles pneumatic A Remove the plug 1 from the fitting on the left side of the pump in front view B Connect a 4 6 hose 2 to the coupling on one end and to the metering equipm...

Page 158: ...Pneumatic Wiring 158 Fit the regulator Install the regulator of the air equipment respecting the direction of assembly the direction of air circulation is given by the arrow 1...

Page 159: ...control Install the side pipe along the motor cylinder passing through the bulkhead from the crankcase on one side and the lower flange of the motor on the other hand Connect the direct pilot hose to...

Page 160: ...Pneumatic Wiring 160 Indirect air control...

Page 161: ...161 14 Filter Install filter Observe the direction of the arrows 1 for circulation of the product Note The filter can be mounted in the up or down position In this manual it is shown in the lower pos...

Page 162: ...nd C It is possible to change the position of the product output by first removing the 4 nuts and washers to disconnect the fluid section part on which the filter is mounted of the motor Note B possib...

Page 163: ...To install a second spray gun on the filter first remove the cap with a 14 mm BTR wrench located on the filter base B Glue and screw the connection with a 32 mm open end wrench to the empty location...

Page 164: ...ng a BTR key of 8 B Using a flat wrench of 27 rotate the filter by 180 C Install the valve 1 at the other end of the filter by turning it 180 replace the cap 2 at the top of the filter with waterproof...

Page 165: ...disassemble the filter Place the integral key 1 against the corresponding projections on the filter ring 2 Unscrew the ring 2 and remove the filter to access the filter elements 3 to change them Tools...

Page 166: ...in the pump cane or hopper Solvent the recirculating pump with solvent using the filter valve and the 1 5 m hose option and drain the pump In case of replacement of the hopper strainer Lift the hopper...

Page 167: ...Operations Dismantling Reassembling the C160 Fluid section 167 Stop the pump in the low position Fluid section rod in low position...

Page 168: ...PTFE O ring Release the axle brake 1 from the groove above the locking ring 2 to disengage the coupling nuts 3 Remove the 4 nuts with a 24 mm open end wrench Disconnect the motor from the fluid sectio...

Page 169: ...Operations Dismantling Reassembling the C160 Fluid section 169 With the regulator Put the motor rod in the up position With the valve Close the valve 1...

Page 170: ...Operations Dismantling Reassembling the C160 Fluid section 170 Remove the cover...

Page 171: ...Operations Dismantling Reassembling the C160 Fluid section 171 Unscrew the 4 screws CHC 1 with a key BTR of 6 mm Remove the flange 2 manually Tools needed 6...

Page 172: ...tridge body 1 remove the cartridge 1 spring cartridge 2 spring 3 male seal press 4 8 V seals 5 and 6 adjustment wedges 8 positioning it Change the V 5 and 6 joints taking care to respect the order of...

Page 173: ...h suction cane option Remove the suction rod with a mallet keeping it at the elbow With hopper option Unscrew the knurled nut manually by a few millimetres Unscrew the nut from the fitting with a 55 m...

Page 174: ...mp hopper assembly to access the suction valve Unscrew the knurled nut 1 manually by a few millimetres Unscrew the nut from the fitting 2 with a 55 mm wrench Rotate the hopper 3 to access the suction...

Page 175: ...75 Clean and or replace the ball carbide seat with rod option If cleaning and or replacement ball seat carbide with option rod With the filter key 1 Unscrew the nut from the pump foot 2 And Pull out t...

Page 176: ...aning the carbide seat and changing the seal Clean the carbide seat 1 with a solvent soaked cloth To change the seal 2 Remove the seal with a flat screwdriver and replace it To change the carbide seat...

Page 177: ...Operations Dismantling Reassembling the C160 Fluid section 177 Unscrew all the filter part option with a 27 mm open end wrench unscrew at the fitting Tools needed 27...

Page 178: ...ke 1 above the locking ring 2 and disengage the coupling nuts 3 Unscrew the 4 nuts and the washers with a spanner of 24 mm Attention Good support fluid section fluid section weight 11 kg 24 25 lbs Dis...

Page 179: ...Operations Dismantling Reassembling the C160 Fluid section 179 Manually remove the cover...

Page 180: ...0 Fluid section 180 Manually Position the fluid section assembly in the jaws of the vice in horizontal position at the tie rods 1 Weight of the fluid section unit 11 kg 24 25 lbs Put martyr s wedges 2...

Page 181: ...Operations Dismantling Reassembling the C160 Fluid section 181 To remove the pump foot Unscrew the nut with the filter key 1 Remove the assembly 2 and the ball 3 Tools needed...

Page 182: ...Operations Dismantling Reassembling the C160 Fluid section 182 Unscrew the 4 nuts with a spanner of 24 mm open end wrench and the washers Tools needed 24...

Page 183: ...Operations Dismantling Reassembling the C160 Fluid section 183 With a mallet remove the valve body with snap ring Tools needed...

Page 184: ...ring out of its seat and change the workpiece In case of change position of the snap ring Manually press the snap ring out of its seat and change position When changing the PTFE seal 909420311 Remove...

Page 185: ...of no prior change of the upper joints Unscrew the 4 screws CHC with a key BTR of 6 mm Remove the flange manually Remove Cartridge spring cartridge spring press male seal 8 V seals with a flat screwdr...

Page 186: ...Operations Dismantling Reassembling the C160 Fluid section 186 If change of seals Position the piston in the jaws of the vise at the flats of part Tools needed...

Page 187: ...the seals by replacing them with new ones grease If change of the pin Position the piston in the jaws of the vice at the flats of the discharge valve With a flat wrench Unscrew the discharge valve at...

Page 188: ...L28 pin Longer travel possible to empower the suction Viscous material Bottom position L30 Pin Avoid the ball to lift too much to shorter the closing time due to viscosity Each pump are mounted as fo...

Page 189: ...t cylinder To remove the cylinder presence of paint tap with the mallet Using the vice and tightening the clamp vertically Unscrew the 4 tie rods with a 19 mm wrench Reassembly Attention Vertical wind...

Page 190: ...190 15 2Reassembly Replace together the 4 lower spacers 27 and the new seals 24 and 25 grease Position the pin in the flap Put the ball in place Screw the discharge valve manually onto the flat surfac...

Page 191: ...in the fluid cylinder discharge valve first Push the flats 1 of the discharge valve out of the cylinder Secure the stem with a 24 mm open end wrench and tighten the discharge valve to 150 Nm with a 32...

Page 192: ...Operations Dismantling Reassembling the C160 Fluid section 192 Reassemble the rod in the produced cylinder using a mallet respecting the above dimension Tools needed...

Page 193: ...Operations Dismantling Reassembling the C160 Fluid section 193 Manually position the O rings in the flange Grease the seals Tools needed Kluber petamo HY 133N...

Page 194: ...Operations Dismantling Reassembling the C160 Fluid section 194 Insert the fluid cylinder into the flange...

Page 195: ...Operations Dismantling Reassembling the C160 Fluid section 195 Screw the 4 tie rods with a 19 mm torque wrench to the 100 N m torque Tools needed 19...

Page 196: ...rations Dismantling Reassembling the C160 Fluid section 196 Manually press the locking ring 2 into its seat at the desired height Manually place the O ring 1 and grease Tools needed Kluber petamo HY 1...

Page 197: ...Operations Dismantling Reassembling the C160 Fluid section 197 Use a mallet to insert the valve body with the locking ring Tools needed...

Page 198: ...Operations Dismantling Reassembling the C160 Fluid section 198 Insert the washers Screw the 4 nuts with a 24 mm torque wrench to the 100 N m torque Tools needed 24...

Page 199: ...Operations Dismantling Reassembling the C160 Fluid section 199 Manually place the ball 3 Screw on the nut with the wrench 1 Loosen the key 1 with a mallet Tools needed...

Page 200: ...5 and 6 and the 4 spacers 7 between the parts 2 and 4 Grease the rafter joints inside and outside Place the rafter piece seal assembly spring cartridge male seal press into the cartridge 1 Place the...

Page 201: ...Operations Dismantling Reassembling the C160 Fluid section 201 Manually place the flange crew the 4 CHC screws together with a 6 mm BTR wrench Tools needed 6...

Page 202: ...Operations Dismantling Reassembling the C160 Fluid section 202 Put the cover on...

Page 203: ...r rod Position the axle brake 1 and locking ring 2 on the motor rod Lower the motor rod again when in contact with the fluid section piston Place the coupling nuts 3 Lower the locking ring 2 and posit...

Page 204: ...carried out via a lifting device Sling on the pallet the pump assembly and wall bracket with lifting means by the motor ring Present the pump and support assembly on the wall or metal frame Secure th...

Page 205: ...Spare parts 205 17 Spare parts Use only genuine SAMES KREMLIN accessories and spare parts designed to withstand the pump s operating pressures 17 1Motor Model 7000 stroke 120...

Page 206: ...2 11 84 193 Outer bearing seal 2 12 85 022 Inner bearing seal 2 13 146 371 013 Pulling x4 1 14 963 040 023 Washer MU 12 8 15 953 010 023 Nut HM 12 8 16 146 371 003 Flange 2 17 909 130 378 Piston seal...

Page 207: ...Spare parts 207...

Page 208: ...Spare parts 208...

Page 209: ...CHc M 6x100 4 44 552 431 Elbow 1 4 MF 1 45 552 542 Fitting 1 4 G 1 46 903 080 401 Relief valve 1 47 88 981 Screw CHc M 8x140 4 48 146 371 024 Muffler foam 1 49 146 371 023 Silencer casing 1 50 905 21...

Page 210: ...17 x 2 22 24 x 2 41 x 4 1 Recommended maintenance parts N S Denotes parts are not serviceable Ind Reference Description Qty 62 88 153 Screw CHc M 8x30 8 63 146 371 005 Socket 1 64 552 251 Fitting 1 8...

Page 211: ...Spare parts 211 17 2 Fluid section Model C160 Ref Fluid section 144050402 144050403 144050404 144050405...

Page 212: ...port 1 10 906 250 011 Pin L 30 mm 1 11 144 050 017 Female joint washer 1 12 907 414 244 Ball 16 stainless steel 1 13 144 050 040 Discharge valve carbide 1 14 909 420 311 PTFE O ring 3 15 144 050 024 F...

Page 213: ...0 319 701 Spring 1 13 144 050 040 Discharge valve 1 12 907 414 244 Ball 16 stainless steel 1 11 144 050 017 Female joint clamp 1 7 144 050 037 Male joint clamp 1 6 144 050 032 Spring cartridge 1 20 14...

Page 214: ...ring PTFE 3 Recommended maintenance parts N S Denotes parts are not serviceable Assembly of the joints Note It is recommended to run in the seals for 10 minutes at 6 bar 87 psi air pressure at a rate...

Page 215: ...ing PTFE 3 Recommended maintenance parts N S Denotes parts are not serviceable Assembly of the joints Note It is recommended to run in the seals for 10 minutes at 6 bar 87 psi air pressure at a rate o...

Page 216: ...1 O ring PTFE 3 Recommended maintenance parts N S Denotes parts are not serviceable Assembly of the joints Note It is recommended to run in the seals for 10 minutes at 6 bar 87 psi air pressure at a r...

Page 217: ...sure at a rate of 6 cycles min before starting the pump Ind Reference Description Qty 144 050 415 Pack of seals 1 24 N C N S Chevron seal UHMWPE 7 26 N C N S Chevron seal PTFE G 7 27 144 050 034 Adjus...

Page 218: ...Spare parts 218 17 3 Spare Parts Product Filter 3 4 Model 500 bar 7252 psi...

Page 219: ...Stainless steel 1 6 906 333 105 Chemical Nickel Gas Cap3 4 1 7 905 210 517 Fitting 3 4 G x 3 8 NPSM 1 8 055 190 007 Stop ring 1 9 150 040 327 Seal the 5 1 10 055 190 005 Stainless spring 1 11 155 581...

Page 220: ...106 Screen n 6 168 1 000 161 108 Screen n 8 210 1 000 161 112 Screen n 12 280 1 2 000 161 115 Screen n 15 360 1 000 161 020 Screen n 20 510 1 000 161 030 Screen n 30 750 1 100 161 104 Set of 25 scree...

Page 221: ...14 343 Carbide ball 30 1 909 420 311 O Ring PTFE 58 1 151 590 510 Pump bracket 1 151 590 511 Pump bracket for air supply 1 151 240 010 Bracket for rod 2 1 550 011 Straight nipple MM 1 4 G stainless st...

Page 222: ...22 Accessories Ind Pos 16 Ind Reference Description Qty 16 149 030 017 Wrenching wrench 1 Ind 17 Ind Reference Description Qty 17 151 590 105 Air supply 1 30 903 130 517 Regulator 31 903 130 518 Regul...

Page 223: ...Ind 19 Ind 22 Ind Reference Description Qty 18 149 597 200 Suction rod 1 1 4 L 600 1 22 150 104 106 Straight fitting M 1 1 4 G M 2 G 1 149 597 250 Suction rod 1 1 4 L 1000 1 19 149 596 153 Strainer f...

Page 224: ...itting MM 1 2 NPSM stainless steel 500 bar 7252 psi 1 905 210 516 Straight fitting M 3 8 NPSM M1 4 NPSM Carbide 500 bar 7252 psi 1 150 104 101 Straight fitting M 1 2 NPSM M1 4 NPSM stainless steel 500...

Page 225: ...27 Ind Reference Description Qty 23 151 590 700 Cart 1 151 590 565 Cart handle screws 1 27 056 100 199 Mounting bracket with bracket 1 Ind 24 Ind Reference Description Qty 24 125 010 000 Hopper 20L a...

Page 226: ...160 060 Heater model MAGMA 500 DI9 400V 3800W M 1 2 JIC refer to doc 582 104 110 1 156 160 010 Heater model MAGMA 500 DI14 230V 3500W M 3 4 JIC refer to doc 582 104 110 1 156 160 020 Heater model MAGM...

Page 227: ...i refer to doc 582 094 110 1 050 500 207 Hose PA 15M 3 8 NPSM 500 bar 7252 psi 1 905 210 516 Nipple MM 3 8 NPSM 1 4 NPSM 1 050 500 401 Hose 1 4 NPSM 1 6m 500 bar 7252 psi 1 129 670 405 Swivel fitting...

Page 228: ...steel 200 mesh 74 Red 04 XX 06 XX 1 129 740 181 PA 1 129 740 082 Stainless steel 150 mesh 100 Blue 06 XX 12 XX 1 129 740 182 PA 1 129 740 083 Stainless steel 100 mesh 149 Yellow 12 XX 18 XX 1 129 740...

Page 229: ...4 07 14 09 14 11 14 13 14 15 14 17 14 19 217 317 417 517 617 717 817 0 019 18 0 95 1 61 2 27 Yellow 100 12 55 18 07 18 09 18 11 18 13 18 15 18 17 18 19 219 319 419 519 619 719 819 0 021 25 1 33 2 25 3...

Page 230: ...ICATION 050 XXX X X X Working pressure Hose lenght 350B 350 1 0 5 m 19 68 500B 500 2 1 m 39 37 3 1 6 m 63 Diameter 4 3 m 118 1 5 7 5 m 295 3 6 10 m 393 7 6 35 1 4 1 7 15 m 550 55 9 5 3 8 2 8 30 m 1181...

Page 231: ...350 302 050 350 152 050 350 252 050 350 352 1 6 m 63 050 350 103 050 350 203 050 350 303 050 350 153 050 350 253 050 350 353 3 m 118 1 050 350 104 050 350 204 050 350 304 050 350 154 050 350 254 050...

Page 232: ...500 302 050 500 152 050 500 252 050 500 352 1 6 m 63 050 500 103 050 500 203 050 500 303 050 500 153 050 500 253 050 500 353 3 m 118 1 050 500 104 050 500 204 050 500 304 050 500 154 050 500 254 050...

Page 233: ...Appendices 233 18 Appendices 18 1 D claration EU and UKCA of incorporation Refer to the existing declaration delivered with the product...

Page 234: ...ce 13 chemin de Malacher 38 240 MEYLAN FRANCE Tel 33 0 4 76 41 60 60 Herewith declares that the sub assembly Pump 72C160 with part numbers 3 72160 3 1 7 15 2 5 3 72160 3 1 1 15 2 5 3 72160 3 4 1 15 2...

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SAMES KREMLIN AZUR 72C160, Manual

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