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SAMES KREMLIN REXSON 4B570 User Manual Download Page 25

Technical characteristics 

25 

 

6.2

 

Principle of operation 

 

Expected use 

These pumps coupled to air or hydraulic motors are  intended for 
transferring or spraying different liquid or pasty products with a desired 
flow rate and output pressure. 

 

Functional description 

 

When the piston (1) rises, check-valves 2 and 5 close, while check-
valves 3 and 4 open. The piston (1) expels the product from the upper 
chamber (V2) to the outside and sucks the product to fill the lower 
chamber (V1). 

When the piston (1) is lowered, check-valves 2 and 5 open, while 
check-valves 3 and 4 close. The piston (1) sucks in the product to fill 
the upper chamber (V2) and expels the product from the lower 
chamber (V1) outwards. 

 

 

 

Summary of Contents for REXSON 4B570

Page 1: ... PUMP 570 cm3 Pump REXSON 4B570 User Manual 582182110 2021 10 28 Index B Translation of the original instructions SAMES KREMLIN SAS 13 Chemin de Malacher 38240 Meylan www sames kremlin com 33 0 4 76 41 60 60 ...

Page 2: ...ny form whatsoever and any exploitation or communication of its contents are prohibited except with the express written consent of SAMES KREMLIN The descriptions and features contained in this document are subject to change without notice SAMES KREMLIN 2021 ...

Page 3: ...4 1 Rexson parts number of High Viscosity Pumps 17 4 2 Table 1 Fluid Section Air Motor Selection 18 4 3 Table 2 Fluid Section Pump Foot Material Selection 18 4 4 Table 3 Seals Pack Selection 18 5 Identification 19 5 1 Description of the marking of the plate 19 5 2 Correspondence table New part numbers Significant designations 21 5 3 Correspondence table Existant part numbers Significant designatio...

Page 4: ...Causes of faults Remedies to apply 33 10 Maintenance 35 10 1 Preventive Maintenance Plan 36 Fluid section 36 10 2 General preconisation maintenance 37 11 Disassembly Reassembly Operation 38 Greases and thread lockers designations 38 Disassembly of the pump 41 Flange 41 Lower or upper cup seals 42 Piston 42 Inlet unit valves 44 Outlet unit valves 44 12 Spare parts 45 Lower adapter flange 48 Recomme...

Page 5: ...thank you for it We have taken the utmost care from design to manufacture so that this equipment gives you complete satisfaction For a good use and an optimal availability we invite you to read this manual carefully before using your equipment Additional Documentations Documentation Reference Air Motor 7200 582144110 Air Motor 9200 582145110 IMPORTANT Before assembly and start up please read and c...

Page 6: ...ciate The warranty 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 limited to the repair or exchange of parts returned to our factory and recognized as defective by us and does not cover the listed wear parts Any costs resulting from the operation cannot...

Page 7: ...Declaration of Conformity 7 1 Declaration of Conformity Refer to the existing declaration delivered with the product ...

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 be supplied or approved by SAMES KREMLIN The equipment must be checked periodically Defective or worn parts must be replaced Never exceed the maximum working pressures of the equipment components Alwa...

Page 9: ...tion Danger hot parts or surfaces Danger flammability risks Danger electricity Risk of explosion Danger user Warning Danger Gloves required Grounding Protective helmet Hearing protection Mandatory respiratory protection Safety shoes Protective clothing Protective visor Safety glasses is mandatory Refer to the manual instruction leaflet ...

Page 10: ...components Danger of Pressure Safety requires that a pressure relieve shutoff valve be mounted on the pump motor supply circuit to allow trapped air to escape when the air supply is shut off Without this precaution the residual air from the engine may cause the motor pump to operate and cause a serious accident Similarly a material bleed valve must be installed on the material circuit so that mate...

Page 11: ...ng 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 Before operating the Pump supply system make sure that all Pump equipment and material containers are grounded To ensure good ventilation Keep the work area clean and free of rags papers solvents Do not operate elect...

Page 12: ... the application in a container designed for that purpose Treat product waste with the legislation of the country where the equipment is used To wear protective clothing designed for that purpose Wearing goggles hearing protectors gloves shoes coveralls and masks for the respiratory tract Attention The use of halogenated hydrocarbon solvents and products containing these solvents in the presence o...

Page 13: ...ir motor is intended to be coupled to a pump Never modify the coupling system Keep hands away from moving parts The moving parts must be kept clean Before commissioning or using the motor pump read carefully the DECOMPRESSURIZATION PROCEDURE Check the proper operation of the pressure relief and bleed air valves Tubing Recommendations Keep hoses away from traffic areas moving parts and hot areas Ne...

Page 14: ...herent 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 potential dangers inherent to the implemented products such as Toxic vapors Fire Explosions It will determine the risks of immediate reactions or due to repeated exposures to the staff SAMES KREMLIN decline...

Page 15: ...cs will be earthed with the earth cable of this motor This earth cable must be connected to a safe earth Have the earth continuity checked by a qualified electrician If earth continuity is not assured check terminal wire and grounding point Never operate the equipment without solving this problem Do not store more flammable products than necessary inside the work area These products must be stored...

Page 16: ... designed and manufactured with high quality materials and components that can be recycled and reused European Directive 2012 19 EU applies to all devices marked with this logo crossed out bin Find out about the collection systems available for electrical and electronic devices Comply with the rules in your area and do not dispose of old appliances with household waste Proper disposal of this old ...

Page 17: ... of thick products 50000 cP Different configurations are available Significant designation Ex 1 cP 1 mPa s 4B R E X 0570 Technology Ball pump 4B Air Motor None XX Motor 7200 72 Motor 9200 92 Refer table 1 Material of construction CS Mixed materials SS Stainless steel Refer table 2 Pump foot G1 GAZ 1 Female Refer table 2 Seal pack PU 06 PEEK 07 Refer table 3 Product Family High Viscosity Pump REX 4...

Page 18: ...pump Available material CS SS Mixed materials Stainless steel G1 1 F BSPP 4 4 Table 3 Seals Pack Selection Available Seals Packing Static seals O rings Upper seals packing Piston seals packing 06 PU FKM PU and PE PE and PTFEV 07 PEEK FKM PEEK and PTFEG PEEK and PTFEG 4B R E X 0570 4B R E X 0570 PTFE Polytetrafluorothylene Teflon like properties PTFEG PTFE Graphite impregnated PE Polyethene UHMWPE ...

Page 19: ... Voltage Directive 2006 95 EEC EMV Directive 2004 108 EEC Safety of machinery Basic terms general implementation guidelines DIN EN ISO 12100 T1 T2 Safety of machinery Temperatures of touchable surfaces EN 563 Safety of machinery Safety engineering requirements for fluid power systems and their components Pneumatics EN 983 ATEX Directive 2014 34 EU II 2 G Group II Category 2 Gas ...

Page 20: ...t pressure Bar Psi AIR Maximum air pressure Bar Psi RAPPORT RATIO Pump pressure ratio CE EC European conformity II2G Use in explosive area II group II 2 category 2 Surface material intended for an environment in which explosive atmospheres due to gases vapors mists are likely to occasionally occur during normal operation G gas IIA T3 IIA Reference gas for equipment qualification T3 Maximum surface...

Page 21: ...mber Significant Designation 63 MO 0570 M S F 000 REX4B0570 MO MA FO SE Options MO Motor MO 55 MOT7200 72 56 MOT9200 92 M Material MA 1 Mixed Steels CS 2 Stainless Steel SS S Seal SE 6 PU 06 7 PEEK 07 F Foot FO 1 1 F BSPP G1 Documentation Reference Air Motor 7200 582144110 Air Motor 9200 582145110 ...

Page 22: ...F BSPP 06 PU 47 224 135 REX4B0570 72 CS G1 06 MOT7200 33 1 CS Mixed Steels G1 1 F BSPP 06 PU 49 224 135 REX4B0570 92 CS G1 06 MOT9200 53 1 CS Mixed Steels G1 1 F BSPP 06 PU 998 910 800 REX4B0570 H1 CS G1 06 Hydraulic motor 200 mm CS Mixed Steels G1 1 F BSPP 06 PU 104 135 00 08 REX4B0570 XX CS G1 07 None CS Mixed Steels G1 1 F BSPP 07 PEEK 49 225 743 REX4B0570 92 SS G1 06 MOT9200 53 1 SS Stainless ...

Page 23: ...struction and seal kit Packings Depending on seal kit Available Motors Motor selection XX 72 92 NONE MOTOR 7200 MOTOR 9200 Pressure Ratio 33 1 53 1 Maximum Air Inlet Pressure bar 6 6 psi 100 100 Maximum Outlet Fluid Pressure bar 200 320 psi 2900 4600 Minimum Outlet Fluid Pressure bar 50 80 psi 718 1153 Complete Pump Weight Kg 111 120 Lbs 244 8 264 8 Air consumption 15 Cycles min 4 bar NL min 1 112...

Page 24: ...Cup Carbon steel Zinc treatment Stainless steel Upper body Carbon steel Zinc treatment Stainless steel Cylinder Carbon steel Chromium treatment Stainless steel chromed Piston Rod Stainless steel chromed Stainless steel chromed Nut Carbon steel Zinc treatment Stainless steel Ball Carbon steel Stainless steel Seat Carbon steel Stainless steel ...

Page 25: ... Functional description When the piston 1 rises check valves 2 and 5 close while check valves 3 and 4 open The piston 1 expels the product from the upper chamber V2 to the outside and sucks the product to fill the lower chamber V1 When the piston 1 is lowered check valves 2 and 5 open while check valves 3 and 4 close The piston 1 sucks in the product to fill the upper chamber V2 and expels the pro...

Page 26: ... the product inside the pump and its accessories as well as that caused by the seals creates static electricity that can cause fire or explosion Therefore the fluid section system must be earthed via the motor ground cable see the motor instruction manual for its ground connection ...

Page 27: ...the order in which the cables hoses and pipes are connected is in accordance with the connection diagram Make sure that all cable connectors hose and pipe connections are correctly fitted Remember that unconnected or incorrectly connected cables hoses and pipes can lead to malfunctions that endanger the safety of operating personnel 7 2 1 Fluid supply connection If the supply pressure is higher th...

Page 28: ...sure drops 7 3 Storage Pump Place the equipment away from moisture after closing the various air inlets and various openings plugs Storage before installation Storage ambient temperature 0 50 C Protect the unit against dust water runoff moisture and shocks Storage after installation Protect the unit against dust water runoff moisture and shocks ...

Page 29: ... removed by flushing with a suitable solvent At the end of the day flush with a suitable solvent It is advisable to stop the fluid section in the low position in order to prevent the product from taking hold of the piston rod Motor The Air motors are tested before their shipment Nevertheless Before coupling the Air motor to a fluid section pump it is recommended to run the air motor at a low air p...

Page 30: ...ghtening Tightening of the Wet Cup Verify cup is filled with lubricant T Run the pump then tighten the cup after 10 minutes again after 1 hour then after 1 day of operation In the event of a leak the cup must be tightened Tightening procedure Depressurize the Air motor see depressurization procedure Depressure the product circuit see depressurization procedure Tighten the cup clean it and fill it ...

Page 31: ...al resulting from the destruction the occultation or the total or partial removal of the protectors 9 3 Start up Pumps are tested for operation at the factory using a light weight oil lubricant Before commissioning this lubricant must be removed by flushing with a suitable solvent At the end of the day flush with a suitable solvent It is advisable to stop the fluid section in the low position in o...

Page 32: ...ut off valve to remove residual air from the motor Unlock the gun valve tap Bring the gun valve tap close to a metal bucket in order to recover the product Hold it against the wall of the bucket to avoid interrupting the grounding continuity if necessary use the wire with clamp to ground the metal bucket Open the gun valve tap in order to drain the circuit Lock the gun valve tap on OFF position Op...

Page 33: ...p with the piston in the low position Fill the lubricant tank Product compatibility seals Check The pump is stopped The fluid is polymerized hardened dried in the pump Clean the pump change the parts if necessary One of the packing nut is too tightened Loosen the packing nut Broken part s in the pump Remove check replace The motor seems to operate but the pump does not deliver product Internal par...

Page 34: ...to the motor valve insufficiently open air leak Check adjust Insufficient air inlet on the motor or outlet clogged hose not adapted Check filter mounting hose not adapted Packing nut or head piston seals too tightened Check mounting or loosen Packing nut Abnormal operating after racing or to elevated temperature Head piston or Packing nut too tightened damaged Check mounting reduce pumping rhythm ...

Page 35: ...r only the most common problems If the information given here does not solve the problem you are experiencing please contact your local SAMES KREMLIN representative for assistance During prolonged shutdown stop the pump when the piston is in the low position 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 b...

Page 36: ... Check the condition of the hoses Observe the piston rod of the pump Do not let the product dry onto the piston rod Check the lubricant level inside the cup keep it at half level Fill it if necessary It is normal for this lubricant to stain Tighten the packing cup moderately with the supplied wrench if necessary Check the tightness of the components If the pump is equipped with a pusher plate chec...

Page 37: ... damaging the seals Install new parts if necessary 10 2 General preconisation maintenance ATTENTION Before any pump maintenance or service work performed it is imperative to follow the depressurization procedure and the safety instructions Before each reassembly Clean the parts with the appropriate cleaning solvent Fit new seals if necessary after greasing them Grease the piston and the inside of ...

Page 38: ...ean the parts with appropriate cleaning solvent Fit new seals if necessary after greasing them Grease the piston and the inside of the cylinder to avoid damaging the seals see table below Fit new parts if necessary Greases and thread lockers designations Index Instruction Description Part number A 1 Grease PTFE Téflon TECHNI LUB grease 10 ml 0 003 US gal 560 440 101 A 2 Anti seize grease Grease bo...

Page 39: ...sembly Reassembly Operation 39 Fluid Section PU Seals version REX4B0570 06 For a full description of spare parts see Part 12 Spare Parts A 2 C 2 C 1 T S 1 C 1 C 1 C 1 C 1 C 1 T T T T T T T T T T A 2 A 2 A 2 ...

Page 40: ...embly Reassembly Operation 40 Fluid Section PEEK Seals version REX4B0570 07 For a full description of spare parts see Part 12 Spare Parts C 2 A 2 C 1 T S 1 C 1 C 1 C 1 C 1 C 1 T T T T T T T T T T A 2 A 2 A 2 ...

Page 41: ...from the pump bracket Take off the pump Flange Unscrew the 2 screws 22 Take off the protective tube 21 Drain and dismount the lubricate assembly which consists of the tank cover 33 the tank 31 the elbow 30 the sleeve 29 Unscrew the cup nuts 3 Unscrew the 4 nuts 27 Remove the washers 28 Take off the lower flange assembly check and replace if necessary the O Rings 32 Remove the inlet 40 and outlet 4...

Page 42: ...up nut 3 Take off check and change if necessary in the following order the F washer 4 The seals 60 depending upon version rerfer to seal pack 06 07 the M washer 6 Take off check and change if necessary the O Rings 23 45 Clean all the parts check them if there are damaged or worn change them Clean and reinstall the parts in the reverse order of the disassembly sequence Piston Take off the rings 38 ...

Page 43: ...nstall the two stop bushes 37 Install the rings 38 on the piston rod 17 Lubricate the packing Insert the lower part of the cylinder 41 in the reverse order of the Chevron seals until reaching the seals and recovering them Install the other Chevron seals upper packings as well as the F washer the seals the M washer on the piston 35 Install the stop bushes 37 Install the rings 38 Make the cylinder s...

Page 44: ...n changing it you must change the ball Clean and reinstall the parts in the reverse order of the disassembly sequence Outlet unit valves Unscrew and take off the terminals 10 Take off check and change if necessary the O Ring 9 and the first seal 11 Take off check and change if necessary in the following order the second O Rings 11 the seats 16 the balls 14 the springs 13 the spacers 15 the retaini...

Page 45: ...genuine SAMES KREMLIN accessories and spare parts designed to withstand the pump s operating pressures Fluid Section PU Seals version REX4B0570 06 WARNING these parts are not supplied with the fluid section alone as they depend on the engine ...

Page 46: ...Spare parts 46 Fluid Section PEEK Seals version REX4B0570 07 WARNING these parts are not supplied with the fluid section alone as they depend on the engine ...

Page 47: ...r 207 819 210 212 4 16 Seat 207 818 210 211 4 2 17 Piston rod 207 820 210 214 1 2 18 M washer 207 832 210 224 2 1 20 F washer According to Seals pack composition table 1 1 21 Protective tube 209 307 1 22 Screw model CHc M 5x10 88 120 2 23 O ring 80 025 1 1 25 Plug model 1 4G 906 333 102 552 237 2 26 Flange 207 807 210 203 2 27 Lock nut 91 225 4 28 Washer 91 226 4 29 Sleeve 207 812 210 206 2 30 Elb...

Page 48: ...rding to Seals pack composition table 2 1 69 Adjustment ring According to Seals pack composition table 2 1 Recommended maintenance parts N S Denotes parts are not serviceable Level 1 Preventive maintenance Level 2 Corrective maintenance Level 3 Exceptional maintenance Lower adapter flange Ind Description Ref Qty Spare part level Lower adapter flange for motors 7200 and 9200 110 413 597 1 3 Connect...

Page 49: ...de Composition Use 06 PU FKM Mastics PVC Butyl 07 PEEK Very abrasive material hot material Accessory Ind Description Ref Qty Bottle of lubricant T 125 ml 0 034 oz 149 990 020 1 Option Ind Description Ref Qty 70 Protection 144 265 015 1 Ind 70 ...

Page 50: ...ng 6 4 210 225 211 046 UHMW PTFE V 6 6 211 721 211 722 PEEK PTFE G Lower cup packing 1 3 210 907 84 331 UHMW PU 4 4 211 714 211 715 PEEK PTFE G 69 Adjustment ring 2 211 723 PU PTFE G PU PEEK PU PTFE G UHMW PEEK PTFE G PEEK PTFE G PEEK UHMW PEEK PTFE V PTFE G UHMW PEEK PTFE V PTFE G UHMW PEEK PTFE G UHMW PEEK PTFE V PTFE G UHMW PEEK PTFE V PTFE G UHMW PEEK PTFE G UHMW PEEK PU PTFE G PU PEEK PU PTFE...

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