SAMES KREMLIN REXSON SH930 Page 1 User Manual Download

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SHOVEL PUMP

930 cm

Pump REXSON SH930

User Manual 582181110

2021-03-01

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

Summary of Contents for REXSON SH930

Page 1: ... PUMP 930 cm3 Pump REXSON SH930 User Manual 582181110 2021 03 01 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: ...SON 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 NUMBER SIGNIFICANT DESIGNATION 21 5 3 CORRESPONDENCE TABLE EXISTANT PART NUMBER SIGNIFICANT DESIGNATION 22 6 TEC...

Page 4: ...mptoms of faults 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 ISO FLANSH flange 46 Disassembly 47 Re assembly 54 12 SPARE PARTS 61 Parts 63 Lower adapter flange 65 Recommended Seals pac...

Page 5: ...ment and we 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 Documentation Documentation Reference Air Motor 9200 2 582128110 IMPORTANT Before assembly and start up please read and clearly under...

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: ...sion of thick products 50000 cP Different configurations are available Significant designation Ex 1 cP 1 mPa s SH R E X 0930 Technology Shovel pump SH Air Motor Motor 9200 2 9H Refer table 1 Material of construction SC Stainless steels Carbide valves Refer table 2 Pump foot FP Follower plate PC Plain cylinder Refer table 2 Product family High viscosity pump REX SH R E X 0930 9H SC FP 06 Cycle volu...

Page 18: ...ss steels FP Follower plate PC Plain cylinder 4 4 Table 3 Seals Pack Selection Available Seals Packing Static seals O rings Upper seals packing Piston seals packing Lower Valve seals packing 06 PU FKM PU and PE PTFEG PE and PTFEV PTFE Polytetrafluorothylene Teflon like properties PTFEG PTFE Graphite impregnated PE Polyethene UHMWPE FKM Flouroelastomer Viton like properties PU Polyurethane PTFEV PT...

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: ...umber Significant Designation 62 57 0930 M S F 000 REXSH0930 MO MA FO SE Options MO Motor MO 57 MOT9200 2 9H M Material MA 4 Stainless Steel Carbide valves SC S Seal SE 6 PU 06 F Foot FO 2 Follower plate Ø 105 mm FP 5 Plain cylinder Ø 112 mm PC Documentation Reference Air Motor 9200 2 582128110 ...

Page 22: ...ation Existant part number Significant designation Motor Material Foot Seal 144 251 106 REXSH0930 XX SC PC 06 None SC Stainless Steel Carbide PC Plain cylinder Ø 112 mm 06 PU 151 150 206 REXSH0930 9H SC PC 06 MOT9200 2 60 1 SC Stainless Steel Carbide PC Plain cylinder Ø 112 mm 06 PU ...

Page 23: ...rts Depending on Materials of construction and seals pack Packings Depending on seal pack Available Motors Motor selection XX 9H NONE MOTOR 9200 2 Pressure Ratio 60 1 Maximum Air Inlet Pressure bar 6 psi 100 Maximum Outlet Fluid Pressure bar 360 psi 5200 Minimum Outlet Fluid Pressure bar 90 psi 1305 Complete Pump Weight Kg 165 Lbs 363 8 Air consumption 15 Cycles min 4 bar NL min 1 3358 scfm 118 6 ...

Page 24: ...Stainless steel Pump body Wet Cup Stainless steel Upper body Stainless steel Cylinder Stainless steel chromed Piston Upper check Piston rod Stainless steel chromed Nut Stainless steel Valve cone Carbide Valve seat Carbide Lower valve Lower check Body Stainless steel Cone Stainless steel Seat Stainless steel Foot Rod Stainless steel Shovel Stainless steel Inlet tube Stainless steel ...

Page 25: ... expels the product from the upper chamber V2 to the outside and sucks the product to fill the lower chamber V1 The shovel pushes the product into the pump foot V3 When the piston 1 is lowered the ball check 2 opens the lower check valve 3 closes and the shovel valve 4 opens The piston 1 compresses the fluid in the lower chamber V1 and transfers it to the upper chamber V2 Since the volume of the u...

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: ...at 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...

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: ...tening 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 after1 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 wit...

Page 31: ...l 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 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 posi...

Page 32: ... 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 in the OFF position ...

Page 33: ...s stopped The fluid is polymerized hardened dried in the pump Clean the pump change the parts if necessary The cup is too tightened Loosen Broken part s in the pump Remove check replace The motor seems to operate but the pump does not deliver product Internal parts of the motor failing Check the operating of the motor Defective coupling Check coupling The pump operates but irregular flow Valve clo...

Page 34: ...ton seals or cylinder worn Replace parts Seals incorrectly mounted or damaged Check the mounting change if necessary The pump does not deliver enough pressure Insufficient air pressure 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 Cup or head piston seals too tightened Check...

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: ...s 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 che...

Page 37: ...ed can be 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 the cylinder to avoid damaging the seals Fit new parts if necessary ...

Page 38: ...embly Clean the parts with the 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 Fit new parts if necessary Greases and thread lockers designations Index Instruction Description Part number A 1 PTFE grease TECHNI LUB grease 10 ml 0 0026 US gal 560 440 101 A 2 Anti seize grease Grease box 450 g 0 ...

Page 39: ...ssembly Operation 39 Fluid Section wall mounted Plain Cylinder REXSH930 FP REXSH930 PC For a full description of spare parts see Part 12 Spare Parts A 1 A 1 A 1 A 1 A 1 A 1 A 1 A 1 C 2 C 1 A 1 A 1 A 1 S 1 A 2 A 1 A 1 ...

Page 40: ...Disassembly Reassembly Operation 40 For a full description of spare parts see Part 12 Spare Parts A 1 A 1 A 1 A 1 C 1 ...

Page 41: ...Disassembly Reassembly Operation 41 Disassembly of the pump Lift up the pump using a bridge or a stem ...

Page 42: ...Disassembly Reassembly Operation 42 Unscrew the screw 1 Rotate the protection 2 2 1 ...

Page 43: ...n 43 Using a flat screwdriver disengage the axle brake 1 from the groove above the locking ring 2 in order to release it Manually lift the locking ring 3 and manually remove the coupling nuts 4 underneath REMOVE THE LUBRICANT 1 2 3 4 ...

Page 44: ...Disassembly Reassembly Operation 44 Unscrew the 4 nuts 1 Put aside the protection 3 and the fluid section 4 1 2 3 4 ...

Page 45: ...Disassembly Reassembly Operation 45 Remove the axle brake 1 and the locking ring 2 Remove the 4 tie rods 3 with a 20 mm wrench 2 1 3 ...

Page 46: ...ly Reassembly Operation 46 ISO FLANSH flange Unscrew the 4 screws 1 Remove the ISO FLANSH flange 2 Remove the seal 3 Replace and grease a new seal 3 Place the ISO FLANSH flange 2 Screw the 4 screws 1 1 2 3 1 2 3 ...

Page 47: ...ly Operation 47 Disassembly Unsrew the nut 1 take off the washer 2 Take off the shovel 3 the closing washer 4 and the shovel spacer 5 For the pump model REXSH0930 FP only Take off the seal 6 and the flange 7 1 2 3 4 5 7 6 ...

Page 48: ...ation 48 Unscrew the filling tube 1 with the wrench Take off the seat 2 and the 2 seals 3 Unscrew the lower valve 4 with 2 wrenches Take off the first M washer the cup spacer the seals the second M washer and the cup 5 1 3 2 4 5 ...

Page 49: ...ly Operation 49 Unscrew the valve body 1 with the wrench Take off the first seal 2 Loosen the wetting cup 3 with the cup wrench Take off the piston assembly 4 the piston seat assembly 5 and the shovel rod 6 1 2 3 3 3 4 6 5 ...

Page 50: ...Disassembly Reassembly Operation 50 Remove the pin 1 with a pin driver ø 5 mm Unscrew and take off the shovel rod 2 1 2 ...

Page 51: ...Disassembly Reassembly Operation 51 Unscrew the piston seat assembly 1 Take off the seals 2 3 Take off the M washer 4 Take off the ball 5 and the F washer 6 1 2 3 4 6 5 ...

Page 52: ...bly Operation 52 Unscrew the cylinder 1 with the wrench Take off the second seal 2 Unscrew the wetting cup 3 with the cup wrench Unscew the 12 screws 4 Place 4 screws 4 into the 4 little holes of the cartridge 5 1 2 3 4 5 ...

Page 53: ...he 4 screws 1 to remove the cartridge 2 Remove the cartridge 3 and unscrew the 4 screws 4 Take off the M washer 5 Take off the F washer 6 Take off the cup block 7 Take off the seals 8 Take off the seal 9 Take off the seal 10 1 2 3 4 5 6 9 7 8 10 ...

Page 54: ...pper flange 1 in a vice Grease the seat 2 Place the ball 3 on the seat 2 Place the M washer 4 Grease and place the seals 5 6 between the M washer 4 and the F washer 7 and put it to the piston Screw the piston seat assembly 8 onto the piston 9 1 2 3 4 5 6 7 8 9 ...

Page 55: ...5 Grease the piston 1 and the cylinder 2 Put the piston assembly 1 into the cylinder 2 Grease and place the seal 3 between the cylinder 4 and the upper flange 5 Screw trhe cylinder 6 onto the upper flange 7 GREASE 1 2 2 GREASE 3 4 5 7 6 ...

Page 56: ...rtridge 3 Grease the seal 4 and put it onto the cartridge 3 Grease the F washer 5 the seal 6 the seals 7 the cup block 8 and the M washer 9 Put the M washer 9 the seal 6 the seals 7 the F washer 5 and the cup block 8 into the cartridge 10 Place the cartridge 10 onto the piston 11 1 2 3 4 5 7 6 9 8 10 11 ...

Page 57: ...crews 1 onto the cartridge 2 to the torque of 20 N m Grease the wetting cup 3 and screw it into the cartridge 2 Glue loctite 5572 and screw the shovel rod 4 into the piston seat 5 Tignten the shovel rod 4 Insert the pin 6 with a pin driver ø 5 mm 1 2 3 4 5 4 6 6 ...

Page 58: ...d the seal 3 Place the seal 3 in the valve body 4 then place it onto the cylinder 1 Tighten the valve body 4 Grease the seals 5 6 the two M washer 7 and the cup spacer F 8 Insert them in the lower valve 9 Glue the cup 10 and screw it to the lower valve 9 1 2 3 4 4 5 6 7 7 8 9 10 ...

Page 59: ...sert the first seal 4 into the valve body 5 Place the seat 6 and the second seal 4 Screw the filling tube 7 For the pump model REXSH0930 FP only Place the flange 8 and the seal 9 Place the shovel spacer 10 the closing washer 11 the shovel 12 the washer 13 and the nut 14 Tighten the nut 14 1 2 3 4 5 6 7 8 9 10 11 12 14 14 13 ...

Page 60: ...n 60 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 the cylinder to avoid damaging the seals Fit new parts if necessary ...

Page 61: ...rts designed to withstand the pump s operating pressures Fluid Section wall mounted Plain Cylinder REXSH930 FP REXSH930 PC 1 WARNING these parts are not supplied with the fluid section alone as they depend on the engine A 1 A 1 A 1 A 1 A 1 A 1 A 1 A 1 C 2 C 1 A 1 A 1 A 1 S 1 A 2 A 1 A 1 ...

Page 62: ...Spare parts 62 A 1 A 1 A 1 A 1 C 1 ...

Page 63: ...40 327 1 1 13 Wetting cup 144 250 008 1 2 14 Cup block 210 724 1 2 17 Drain plug 210 431 1 3 18 Cylinder 144 250 002 1 2 19 Seal FKM 84 456 2 1 20 Piston assembly 144 250 015 1 2 21 Piston rod N S 044 250 006 1 3 22 Male washer 210 712 1 3 23 Female washer 210 713 1 3 26 Piston seat assembly 144 250 198 1 2 27 Piston seat N S 044 250 105 1 2 28 Ball Ø 32 carbide 87 532 1 2 29 Pin N S 88 745 1 3 30...

Page 64: ... 1 1 41 Shovel spacer kit 144 250 197 1 2 42 Shovel spacer 210 682 1 2 43 Closing washer 210 683 1 2 44 Stainless steel washer 88 550 1 2 45 Stainless steel nut 88 963 1 2 46 Stainless steel shovel 144 250 101 1 2 50 Flange 2 parts 210 686 1 3 51 Seal 84 457 1 2 Seal kit 144 251 196 1 1 Recommended maintenance parts N S Denotes parts are not serviceable Level 1 Preventive maintenance Level 2 Corre...

Page 65: ...el Lower adapter flange for motor 9200 2 144 245 495 1 3 55 Protective housing N S 051 150 110 1 56 Tie rod N S 051 150 101 4 Recommended maintenance parts N S Denotes parts are not serviceable Level 1 Preventive maintenance Level 2 Corrective maintenance Level 3 Exceptional maintenance ...

Page 66: ...d Seals pack Code Composition Use 06 PU PTFEV Mastics PVC Butyl with a better temperature resistance Accessory Ind Description Ref Qty Bottle of lubricant T 125 ml 0 034 oz 149 990 020 1 Allows a better mechanical resistance é ...

Page 67: ... 210 722 PU PE 19 Seal 2 84 456 FKM Piston packing 3 3 210 726 211 318 PE PTFEV Shovel packing 4 2 211 334 211 335 PE PTFE 39 O ring 2 909 420 509 PTFE 51 Seal 1 84 457 FKM Adjustment block 4 210 724 ST STEEL PU PU PU PU PU PE PE PTFEV PE PTFEV PE PTFEV PE PE PE PE PTFE PTFE 15 24 35 57 15 24 35 Quantity to be assembled as required PTFE V PTFE Glass ...

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