User manual

2K Metering Gear Pumps

0.3 - 0.6 - 1.2 - 2.4 - 6 and 10 cc

SAMES KREMLIN SAS - 13, Chemin de Malacher - 38240 MEYLAN - FRANCE

Tel. 33 (0)4 76 41 60 60 - www.sames-kremlin.com

Index revision : B - March 2018 1 7074

All communication or reproduction of this document, in any form whatsoever and all use or
communication of its contents are forbidden without express written authorisation from
SAMES KREMLIN.

The descriptions and characteristics mentioned in this document are subject to change without
prior notice.

© SAMES KREMLIN 2010

WARNING : SAMES KREMLIN SAS is registered with the Ministry of Labour as a training
institution.
Throughout the year, our company offers training courses in the operation and
maintenance of your equipment.
A catalogue is available on request. Choose from a wide range of courses to
acquire the skills or knowledge that is required to match your production
requirements and objectives.
Our training courses can be delivered at your site or in the training centre at our
Meylan head office.

Training department:
Tel. 33 (0)4 76 41 60 04
E-mail: [email protected]

SAMES KREMLIN SAS operating manuals are written in French and translated into English, German, Spanish, Italian
and Portuguese.
The French version is deemed the official text and SAMES KREMLIN will not be liable for the translations into other
languages.

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2K Metering Gear Pumps
0.3 - 0.6 - 1.2 - 2.4 - 6 and 10 cc
1. Health and Safety Instructions- - - - - - - - - - - - - - - - - - - - - - - - - - - - 4
1.1. Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2. Simplied analysis of the potential sources of ignition
according to Standard EN 80079-36 . . . . . . . . . . . . . . . . . . . . . . 4
1.3. Precautions for Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4. Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.5. Insulation or Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2. Description - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7
3. Characteristics - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7
3.1. General Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2. Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2.1. Pumps 0.3 and 0.6cc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2.2. Pumps from 1.2 to 10 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4. Installation- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10
4.1. General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.2. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5. Start-up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10
6. Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11
6.1. Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.2. Preliminary Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.3. Pump Disassembly Procedure . . . . . . . . . . . . . . . . . . . . . . . 12
6.4. Pump Reassembly Procedure . . . . . . . . . . . . . . . . . . . . . . . 16
6.5. Breaking in the new pump . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7. Cleaning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 22
8. Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 23
9. Spare parts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 24
9.1. 2K Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
9.2. Maintenance kits for 2K pumps 0.3 cc and 0.6 cc . . . . . . 25
9.3. Maintenance kits for 2K pumps from 1.2cc to 10 cc . . . . 26
9.4. Connecting Flanges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Index revision : 3
1. Health and Safety Instructions
1.1. Marking

DES05036
K

Type of the pump: 0,3 2K ADLC, 0,6 2K ADLC, 1,2 2K ADLC, 2,4 2K ADLC, 6 2K ADLC, 10 2K ADLC.
Example:
• Pump 6 cc: 6 2K ADLC P/N: 270000070
Remark: The arrow shows the direction of the pump.

1.2. Simplied analysis of the potential sources of ignition according to Standard EN 80079-36

Action applied to prevent anu igni-

Risk of ignition tion source to become effective
Potential Description / Main cause
source (What are the conditions Description of the applied action
of ignition engendering the ignition risk?)
Heating of the envelope by fric- The maximum surface temperature is
Hot surface tion, internal friction or heat dissi- determined by testing under the
pation most unfavourable conditions
Spark of a Friction of the gears and axes,
Rotation speed is lower than 1m/s,
mechanical loosening, vibrations, breakage of
(see § 3.1 page 7).
origin internal components
All the parts of the pump are metallic
Electrostatic and are connected to each other,
Incorrect grounding
discharge and grounding is required.(see § 1.5
page 6)
Electrostatic For an electrostatic installation,
Insulated pump
discharge respect the rules: see § 1.5 page 6.

This equipment is designed in accordance with ATEX Directive 2014/34/EU and is intended for
use in Zone 1.

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1.3. Precautions for Use
This document contains information that all operators should be aware of and understand
before using this material. This information highlights situations that could result in serious
damage and indicates the precautions that should be taken to avoid them. The equipment
must only be used by personnel trained by SAMES KREMLIN.

1.4. Warnings

WARNING : Safety may be jeopardized if this equipment is not operated, disassembled and
reassembled in compliance with the instructions given in this manual and in any
European Standard or national safety regulations in force.

WARNING : Equipment performance is only guaranteed if original spare parts distributed by

SAMES KREMLIN are used.

Pump assemblies must be kept clean so that it is possible to detect any leaks and their severity.

Electrostatic spraying equipment must be serviced regularly in accordance with the informa-
tion and instructions given by SAMES KREMLIN. The pump specifications must be observed
carefully.

Cleaning operations must be carried out either in authorised areas equipped with a mechani-
cal ventilation system, or using cleaning liquids with a flash point at least 5 °C higher than room
temperature.

The operator must use the protections adapted for the eyes and the skin when the propor-
tioned product presents dangers.
After having carried out repairs, adjustments or cleaning with polluting products, a particular
care will be taken to the ecological elimination of waste.

It is strictly forbidden to any operator to interfere on equipment under operation.

WARNING : Please rinse thoroughly with the proper rinsing solution before each time the pump
is taken apart and make sure that no pressure positive or negative remains.

Any modification of the pump being able to decrease the operating safety is prohibited.

The pump must be used in a surrounding area clear and clean.

Only metal containers can be used for cleaning liquids and they must have a reliable ground
connection

The storage of the pumps or its components must be done in a dry room and safe from dust.

Before the installation of the pump, it is important to store it, as a preliminary, at the temperature
to which the pump will be used in order to avoid any risk of seizing.

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1.5. Insulation or Grounding
Use of these pumps with conductive products must comply with the rules concerning electrical
insulation and enclosure-access reserved for this material. The possibility of the access to the
enclosure must be checked to the switch-off of the high voltage in order to avoid any risk of
electric shocks to the people.
n all cases, the connection equipment must comply with the characteristics relative to the
transport of pressurised liquid products up to 50 bar.

Pumping of conductive products and presence of HV:

• The configuration of the installation will be established by SAMES KREMLIN specialists.
• Any modification without consultation will result in the invalidity of the certificate of
conformity.

Pumping of insulating products with or without the presence of HV:

• It is necessary to connect the pump to the ground with the connection screw located on
the pump.

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2. Description
This pump is designed especially for the metering of paints and products non-charged (Viscos-
ity of 20 to 200 mPas).

All parts in contact with the paint are coated with ADLC.

The normal life under optimal parameters is about 2 years at a rate of 5 days per week and 8
hours per day. This value is igiven as an indication because it can change according to the
metered product.
Products with high viscosity will not be metered in the same way as products with low viscosity.

Product input and output are located on the pump body. The product to be metered is guiding
from the opening to the gears. The set of theeth fills up and drives the product to the exit. The
set of theeth empties when the gear turns and pushes the product through the output opening
by decompression.

Back view of a pump

3. Characteristics
3.1. General Characteristics
• Pressures
• optimal: 3 to 7 bars short 15 bars.
• DP limit : 2 bars
DP : output pressure - input pressure.
Higher DP increases the wear of the pump and decreases the accuracy of the
metering.

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 • Rotation speed. : from 10 rpm to 120 rpm depending on the product (best results obtained
between 30 and 80 rpm).
• Rinsing: Maximum 40 rpm, by pass open.

• Temperature of the metered fluid : 100°C max. for an ambient temperature between -
20°C and 40°C.

• Dosage accuracy.
The accuracy of the dosage of a new pump is between ± 2% within the following opera-
tion conditions:
• Rotation speed between 30 and 80 rpm.
• Rinsing oil viscosity of 25s DIN 4
• Delta P ± 2 bar between input and output.

3.2. Dimensions

3.2.1. Pumps 0.3 and 0.6cc

Dimensions are in mm.

Size 0.3 cc 0.6 cc

X (mm) 41.2 45.4
Weight 1.33 Kg 1.39 Kg

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3.2.2. Pumps from 1.2 to 10 cc

Dimensions are in mm.

Size 1.2 cc 2.4 cc 6 cc 10 cc

X (mm) 41.2 45.4 58 10
Weight 1.91 Kg 2.1 Kg 2.52 Kg 3.03 Kg

Index revision : B - March 2018 9 7074

4. Installation
4.1. General Information
It is advised to clean the pump before its assembly. The inlets / outlets must be free from any
impurities which could block the openings. Observe the direction of the rotation as well as the
inlets/ outlets indicated on the pump. Turn manually the axis of the pump of some turns in order
to check the rotation.

WARNING : Turning the axle of the pump in the bad direction can cause damage and destroy
the pump. The direction of rotation of the pump is defined by positioning the drive-shaft in the
direction of the observer.
It is also advised NOT to run the pump dry.

4.2. Installation
Elements linked to pump operation:
• The pump must be correctly installed on its stand. A perfect alignment between the pump
shaft and the drive shaft must be respected. A minimum distance of 2 mm between the
tip of drive shaft and the pump should be kept and the two should never touch. A radial
pressure on the drive shaft can damage the pump.
• For leak proof connections, use rigid seals in PTFE.
• Check the hoses before and after the pump. In case of impurities at the entrance of the
pump or if the product to be metered is not perfectly clean, a filter must be installed.
• The pump must no be in contact with any other element of the installation and adequate
ventilation must be maintained around the pump.

5. Start-up
When starting the pump, the good sealing of the friction plates will be automatically verified. If
the product leaks between the plates, the tension of the screws must be checked. (see § 6.4
page 16). If the leak persist, take the pump apart. After a good cleaning of the different parts
and a careful check of the surfaces of the friction plates and of the mechanical seal, reassem-
ble the pump (see § 6.4 page 16). A perfect seal is possible only if the surfaces are dry and per-
fectly clean.

The pump is shipped with a liquid barrier which does not require any maintenance.

Make sure that the rotation direction of the pump is correct and inputs/outputs are connected
according to the rotation direction.

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6. Maintenance

WARNING : The metering pump is designed to run in a continuous manner, but can also be used
intermittently. During relatively shorts off periods, no particular maintenance or repair is neces-
sary. The bearings are lubricated by the product metered and therefore it advised NOT to run
the pump dry.

6.1. Tools
• 3/4/5mm hex socket wrench (Dynamometric 8 to 10 Nm).
• 4 mm hex socket wrench.
• Plastic mallet.
• Screwdrivers (Nr 2 and 4).
• Indelebile marker.
• Cleaning paper.
• 1 sheet of paper of glass 1600.
• 1 fine abrasive stone (800 -1000).
• Solvent or hardener compatible with the product in the pump.
• 1 brush (hard) for the ∅ 5mm grooves.
• Protective gear (according to the recommendations given by the manufacturer of the
product to be metered).
• Special tool set for sealing device (P/N 270000089)

6.2. Preliminary Procedures

Before dismantling the pump, the following operations must be carried out:

1 Carry out a rinsing cycle with the suitable solvent, ensure that there are no input and
ouput pressures and complete the cycle by prolonged blowing (4 to 5 seconds),

2 Lock the air and fluid valves, then disconnect the product hoses from the pump after hav-
ing marked their respective positions,

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6.3. Pump Disassembly Procedure

WARNING : A preventive maintenance is advised after 1600 operating hours. All the elements
of the pump must be handled with an extreme delicacy, any shock between the different com-
ponents could harm the future correct operation of the pump.

Step 1

Place the pump in a vice.

Step 2
2

Unscrew the six securing screws of the rear plate

(2) and separate it by carrying out a small rota-
tion using a screwdriver.

Step 3

Remove the o-ring. Clean the rear plate using an

appropriate solvent, pay a particular attention
to the
o-ring groove. The o-ring must be replaced at
each reassembly.

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Step 4
3

Remove the upper part (3) of the pump body.

Remove the two centering round key (4).
4

Step 5

6
5
Withdraw the key or the pin (5) (according to the
size of the pump) from the drive shaft (6).

Step 6 7

Remove the o-ring. Clean the body (7) using an

appropriate solvant, pay a particular attention
to the o-ring groove. The o-ring must be
replaced at each reassembly.

Step 7

Unscrew the three screws of the sealing device

and extract the key (8) from the drive-shaft.

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Step 8

9
Remove the sealing system (9).

Step 9

7
Extract the drive-shaft (6) from the body (7)
using a mallet.

Step 10

10 11
Remove the double lips seal assembly (10) then
the bearing (11).

Step 11 13
12

Remove the o-ring (12) and unscrew the two M

4x 20 screws (13).

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Step 12 16
18 17
19
B
14
Step A: Separate the sealing unit body (14) from
the bracket (15).
A Step B: Remove the seal PTFE (16), the pressure
ring (17), the ball bearing (18) and the intermedi-
15 ate ring (19).

Step 13 19

Using a pin-drift, extract the lip seal (19).

Step 14
21
20

Remove the o-ring (20) and the lip seal PTFE du

from the sealing unit body.

Step 15

Unscrew the M5 x 6 screws.

WARNING : Disassembling may be assisted by tapping with a plastic mallet or by the introduc-
tion of blades made from synthetic material (nylon).
Use of materials that are harder than the pump material may result in permanent damage to
the components.

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6.4. Pump Reassembly Procedure

Step 1

Put in place the tool on the bracket (15).

15

Step 2

Install the lip seal (19) on the tool.

19

Step 3

Place the lip seal on the bracket.

Step 4

Remove the tools.

Index revision : B - March 2018 16 7074

Step 5

Check the conditions of the several compo-

nents, replace if necessary then put back in
place in the bracket.

Step 6

Place the tool on the sealing unit body (14).

14

Step 7

Place the lip seal on the tool.

Step 8

Place the lip seal in the sealing unit body.

Index revision : B - March 2018 17 7074

Step 9

Remove the two tools.

Step 10

Install a new ring on the sealing unit body.

Step 11

Screw the sealing unit body to the bracket.

2 M4 x 20 screws

Step 12

Place a new o-ring on the sealing system.

Index revision : B - March 2018 18 7074

Step 13

Install the bearing and the double lips seal in the

body using the tool.

Step 14

Remove the tool.

Step 15

Screw the sealing system on the body (tighten-

ing torque: 10N.m).

Step 16

Insert the drive shaft in the body.

Index revision : B - March 2018 19 7074

Step 17

Respect the positioning of the drive shaft..

Step 18

Install the centering pins on the body.

Step 19

Place the key or the pin la clavette (according

to the size of the pump) into the drive shaft.

Step 20

Place the upper part on the body.

Index revision : B - March 2018 20 7074

Step 21

Place a new o-ring on the rear plate.

Step 22

Secure the rear plate with the six screws (tighten-

ing torque: 10N.m).

Step 23

Put in place screws and washers, screw with a

tightening torque 5 N.m.

Step 24

Insert the key into the drive shaft.

Index revision : B - March 2018 21 7074

6.5. Breaking in the new pump
It is advised to break it in with the product to be metered.

WARNING : Rinsing a pump is a destructive operation for the pump when the recommendations
are not followed to the point.
Before starting the pump for the first time, a rinsing is necessary. It must be done with the rinsing
product recommended by the paint manufacturer.

WARNING : The rinsing must respect the following conditions:

- The rinsing time must be as short as possible because certain products of rinsing
do not contain lubricant,
- the rotation speed must not exceed 40 rpm.

• Let the pump turn at a rotation speed of 20 to 30 rpm, with product in it, with an input
pressure no to exceeding 3 bars and an outpressure of 0 bar, for one hour (if possible in
close circuit).

• Following the same idea, increase the output pressure to 5 bars and so for 30 minutes.

• Then gradually, increase until the maximum pressure allowed is reached (15 bars), doing
so 30 minutes at a time. During this time, it is possible to calibrate the pump in order to
observe the output curb with the product running, and to compensate for any internal
leakage of the pump by setting the rotation speed.

7. Cleaning

WARNING : The elements will be dipped in the solvent appropriate for the product metered.
Using a nylon brush or flexible scraper, remove the traces of paint and seals remaining on the
components. Dry with compressed air.

The element must never hit anything or be hit anything during this procedure. The parts will be
put in the container with care.

For the cleaning operation, do not use metallic tools as screwdrivers, knives or chisels.

In order not to mix the parts from different pumps, only one pump will be cleaned in one con-
tainer at a time.

The cleaning of a pump is often tedious.

This procedure is however, of prime importance in order to correctly analyse signs of wear and
tear and to ensure perfect assembly, which in turn, ensures successful functioning of the pump.

Index revision : B - March 2018 22 7074

8. Troubleshooting

Symptoms Probable Causes Remedies

Driving shaft worn Remove and check.
Product leaking in Replace if necessary
the drive Sealing unit worn out
Shaft seal Incompatible products or pres- Contact SAMES KREMLIN
sures

Impurities between the plates Take apart and clean the pump.
Allowed pressures exceeded. Check the screw and tighten if
Leakage in the necessary. Lower the pressures.
plates area
Very thin liquid (leak by capillar- Contact SAMES KREMLIN
ity)

Pump elements are worn out.

Take apart and check the pump
Impurities in the Input/Output
No precision in elements as well as the I/O hoses.
hoses. Feeding pressure too
the metering. Check the I/O pressures. Check
weak. Play not adapted to the
the viscosity of the product.
product. Error during assembly

No output (the The motor does not run. The cou- Check the motor and its electrical
pump does not pling is broken or missing. connection. Check the coupling
run) and the keys.

The I/O are poorly connected or Check the I/O connections. Check
No output (the plugged. The pin driving the the feeding of the pump. Take
pump runs) gears is broken. No product apart the pump and check the pin
enters the pump. and the gears.

Index revision : B - March 2018 23 7074

9. Spare parts
9.1. 2K Pumps

DES06943
3

DES06970
Unit Maintenance
Item Part number Description Qty of level for spare
sale parts (*)
910026685 Equipped 2K Pump - 0.3 cc 1 1 3
1 J3STKL011 O-ring - chemically inert 2 1 1
2 270000071 2K Pump - 0.3 cc 1 1 3
910026686 Equipped 2K Pump - 0.6 cc 1 1 3
1 J3STKL011 O-ring - chemically inert 2 1 1
2 270000072 2K Pump - 0.6 cc 1 1 3
910026687 Equipped 2K Pump - 1.2 cc 1 1 3
1 J3STKL011 O-ring - chemically inert 2 1 1
2 270000068 2K Pump - 1.2 cc 1 1 3
910026688 Equipped 2K Pump - 2.4 cc 1 1 3
1 J3STKL011 O-ring - chemically inert 2 1 1
2 270000069 2K Pump - 2.4 cc 1 1 3
910026689 Equipped 2K Pump - 6 cc 1 1 3
1 J3STKL011 O-ring - chemically inert 2 1 1
2 270000070 2K Pump - 6 cc 1 1 3
910026690 Equipped 2K Pump - 10 cc 1 1 3
1 J3STKL011 O-ring - chemically inert 2 1 1
2 270000067 2K Pump - 10 cc 1 1 3
Option
3 854279 Mesamol adaptation - 1 3
H1HMIN037 Mesamol oil - 1 2

(*)
Level 1: Standard preventive maintenance
Level 2: Corrective maintenance
Level 3: Exceptional maintenance

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9.2. Maintenance kits for 2K pumps 0.3 cc and 0.6 cc

1 2

2
2 3

Unit Maintenance
Item Part number Description Qty of level for spare
sale parts (*)
1 270000091 Complete sealing unit 1 1 2

2 270000093 Seal kit for sealing system included 1 1 1

Bearing + axial thrust 1 - -
Double lips seal assembly 1 - -
O-ring 23.52 x 1.78 2 - -
Lip seal PTFE 1 - -
Seal PTFE 1 - -
Lip seal viton 1 - -

3 270000092 Ball bearing 1 1 2

(*)
Level 1: Standard preventive maintenance
Level 2: Corrective maintenance
Level 3: Exceptional maintenance

Index revision : B - March 2018 25 7074

9.3. Maintenance kits for 2K pumps from 1.2cc to 10 cc

2
2 3

Unit Maintenance
Item Part number Description Qty of level for spare
sale parts (*)
1 270000091 Complete sealing unit 1 1 2

2 270000090 Seal kit for sealing system included 1 1 1

O-ring - viton 56.87 x 1.78 2 - -
Bearing + axial thrust 1 - -
Double lips seal assembly 1 - -
O-ring 23.52 x 1.78 2 - -
Lip seal PTFE 1 - -
Seal PTFE 1 - -
Lip seal viton 1 - -

3 270000092 Ball bearing 1 1 2

(*)
Level 1: Standard preventive maintenance
Level 2: Corrective maintenance
Level 3: Exceptional maintenance

Index revision : B - March 2018 26 7074

9.4. Connecting Flanges

A B
2
1
2
1

3
3

C D
2

DES03623
1 3

Unit Maintenance
Item Part number Description Qty of level for spare
sale parts (*)
A 910007407 1 Pressure switch flange Option 1 -
1 270000023 Tightening adapter 1 1 -
2 270000024 O-ring - PTFE 1 1 1
3 J3STKL011 O-ring - chemically inert 2 1 1
B 910007408 1 Pressure switch reverse flange Option 1 -
1 270000023 Tightening adapter 1 1 -
2 270000024 O-ring - PTFE 1 1 1
3 J3STKL011 O-ring - chemically inert 2 1 1
C 910007409 2 Pressure switch flange Option 1 -
1 270000023 Tightening adapter 2 1 -
2 270000024 O-ring - PTFE 2 1 1
3 J3STKL011 O-ring - chemically inert 2 1 1
D 910008031 Fitting fixing flange Option 1 -
3 J3STKL011 O-ring - chemically inert 2 1 1

Remarks: Flanges are used to connect, according to the type, one or two pressure switches.

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 Unit Maintenance
Item Part number Description Qty of level for spare
sale parts (*)
22000068AT Pressure switch (0 to 50 bar) (pump outlet) - 1 3
22000069AT Pressure switch (0 to 16 bar) (pump inlet) - 1 3
900005312 Pressure switch plug - 1 3

(*)
Level 1: Standard preventive maintenance
Level 2: Corrective maintenance
Level 3: Exceptional maintenance

Remarks: Connecting flanges are fitted to the pumps by a Chc M8x 40 screw (P/N X3AVSY287).

Remarks:
1 When a pressure switch is used, it is imperative beforehand to install a tightening adapter
(P/N: 270000023) on the connecting flange.
2 Put in place the o-ring (P/N: 270000024) then the plug (P/N: 900005312), when a pressure
switch exit is not used.

Index revision : B - March 2018 28 7074