SAMES KREMLIN FLOWMAX AIRMIX PU 2160 F User manual

DOCUMENTATION
FLOWMAX® AIRMIX®
PROPORTIONING PUMP
PU 2160 F
Manual : 582.175.110-UK - 2012
Date : 01/12/20
Supersede :
Modif.:
TRANSLATION FROM THE ORIGINAL MANUAL
IMPORTANT :Before assembly and start-up, please read and clearly understand all the documents relating to
this equipment (professional use only).
THE PICTURES AND DRAWINGS ARE NON CONTRACTUAL. WE RESERVE THE RIGHT TO MAKE CHANGES WITHOUT PRIOR NOTICE..
SAMES KREMLIN SAS
l
13, chemin de Malacher
38 240 - MEYLAN - France
 : 33 (0)4 76 41 60 60
www.sames-kremlin.com

SAMES KREMLIN N° : 578.001.130-UK-1804
INSTALLATION AND SAFETY
INSTRUCTIONS
TRANSLATION FROM THE ORIGINAL MANUAL
IMPORTANT :Before assembly and start-up, please read and clearly understand all the
documents relating to this equipment (professional use only).
THE PICTURES AND DRAWINGS ARE NON CONTRACTUAL. WE RESERVE THE RIGHT TO MAKE CHANGES WITHOUT
PRIOR NOTICE.
SAMES KREMLIN SAS
l
13, chemin de Malacher
38 240 - MEYLAN - France
 : 33 (0)4 76 41 60 60
www.sames-kremlin.com

SAMES KREMLIN - 1 - N° : 578.001.130-UK-1804
1. SAFETY INSTRUCTIONS
GENERAL SAFETY INSTRUCTIONS
CAUTION : The equipment can be dangerous if you do not follow our
instructions concerning installation and servicing described in this manual
and in accordance with applicable European standards and local national safety
regulations.
Please carefully read all the instruction literature before operating your
equipment.
Only trained operators can use the equipment.
The foreman must ensure that the operator has understood the safety instructions for this equipment as
well as the instructions in the manuals for the different parts and accessories.
Read carefully all instruction manuals, label markings before operating the equipment.
Incorrect use may result in injury. This equipment is for professional use only. It must be used only for
what it has been designed for. Never modify the equipment. The parts and accessories supplied must be
regularly inspected. Defective or worn parts must be replaced.
Guards (motor cover, coupling shields, connectors,…) have been designed for a
safe use of the equipment.
The manufacturer will not be held responsible for bodily injury or failure and / or
property damage due to destruction, the overshadowing or the partial or total
removal of the guards.
Never exceed the equipment components' maximum working pressure.
Comply with regulations concerning safety, fire risks, electrical regulations in force in the country of final
destination of the material. Use only products or solvent compatible with the parts in contact with the
material (refer to data sheet of the material manufacturer).
PICTOGRAMS
ADFECG
NIP HAZARD WARNING
MOVING
ELEVATOR
WARNING
MOVING PARTS
WARNING
MOVING SHOVEL
DO NOT
EXCEED THIS
PRESSURE
HIGH
PRESSURE
HAZARD
HJLKMQ
RELIEF OR
DRAIN VALVE
WARNING
HOSE UNDER
PRESSURE
WEAR GLASSES
OBLIGATORY
WEAR OF
GLOVES IS
OBLIGATORY
PRODUCT
VAPOR
HAZARDS
WARNING
HOT PARTS OR
AREAS
NPR
ELECTRICAL
HAZARD
WARNING
FIRE HAZARDS
EXPLOSION
HAZARDS
GROUNDING WARNING
(USER)
WARNING
SERIOUS
INJURIES

SAMES KREMLIN - 2 - N° : 578.001.130-UK-1804
PRESSURE HAZARDS
Current legislation requires that an air relief valve be fitted in the air supply circuit to the air
motor to prevent over pressurisation. This safety feature,ensures that it is not possible to supply
the air motor with excessive air pressure that may cause injury.
Please ensure that a material drain valve is fitted in the fluid circuit to drain and depressurise the
circuit. Once depressurised and drained, work /servicing may then commence on the equipment
Please remember to close these valves when restarting the system.
HIGH PRESSURE INJECTION HAZARDS
When working with high pressure equipment, special care is required. Fluid leaks can occur.
There is a risk of material being injected to any exposed parts of body, this could cause severe
injury :
medical care must be sought immediately if paint is injected under the skin or in other
parts of the body (eyes, fingers).
never point the spray gun at any one. Never try to stop the spray with your hands or fingers
nor with rags or similars.
follow the shut down procedure and always depressurize air and fluid circuits before
carrying out any servicing on the gun (cleaning, checking, maintenance of the material or
cleaning of the gun nozzles).
for the guns equipped with a safety device, always lock the trigger when not in use.
FIRE - EXPLOSION - SPARKS - STATIC ELECTRICITY HAZARDS
A poor earth connection, inadequate ventilation, sparks or static electricity can cause an
explosion or fire. to avoid these risks when using or servicing SAMES KREMLIN equipment, the
following safety procedures must be followed :
ensure a good earth connection and ground the parts to be handled i.e. solvents, materials,
components and equipment,
ensure adequate ventilation,
keep working area clean and free from waste solvents, chemicals, or solid waste i.e. rags,
paper and empty chemicals drums,
never use electrical switches / power if in an atmosphere of volatile solvent vapour,
stop working immediately in case of electrical arcs,
never store chemicals and solvents in the working area.
use paint whose flash point is the highest possible to prevent from any formation of gas
and inflammable vapours (refer to materials' safety instructions),
install a cover on the drums to reduce the diffusion of gas and vapours in the spraybooth.
TOXIC PRODUCT HAZARDS
Toxic products or vapours can cause severe injury not only though contact with the body, but also
if the products are ingested or inhaled. It is imperative :
to know the material products and their risks,
notified or hazardous materials must be stored in accordance with the regulations,
the material must be stored in an appropriate container, never place materials in a
container where there is a risk of spillage or leakage,
a procedure must be applied for the safe disposal of waste material. It must comply with all
prevailing regulations and legislations of the country where the equipment is to be used,
protective clothing should always be worn in compliance with the material manufacturers'
recommendations,
depending on the application and chemical safety instructions, safety glasses, hearing
protective earplug, gloves, foot wear, protective masks and possible breathing equipment
should be worn to comply with the regulations (Refer to chapter "Safety equipment of
SAMES KREMLIN selection guide).

SAMES KREMLIN - 3 - N° : 578.001.130-UK-1804
CAUTION!
It is forbidden to use material containing high concentrations of halogenated hydrocarbon
solvents with aluminium or zinc fillers .Non-compliance with the instructions may cause
explosion risk causing serious or fatal injury.
EQUIPMENT REQUIREMENTS
Guards (motor cover, coupling shields, connectors,…) have been designed for
a safe use of the equipment.
The manufacturer will not be held responsible for bodily injury or failure
and / or property damage due to destruction, the overshadowing or the
partial or total removal of the guards.
PUMP
Before carrying out any work, it is imperative to read and clearly understand the disassembly and
reassembly instructions before servicing. The operator must understand the equipment and the
safety instructions. These instructions are available in the equipment manuals.
The air motor is designed to be mounted with a pump. Never modify any components or
couplings. When operating, please keep hands away from moving parts. Before starting up the
equipment, please read the PRESSURE RELIEF instructions. Please ensure that any relief or
drain valves fitted are in good working order.
HOSES
Keep hoses out of circulation areas, moving parts or hot surfaces,
Never expose product hoses to temperature higher than + 60°C / 140° F or lower than 0°C
/ 32° F,
Never pull or use the hoses to move the equipment,
Tighten all fittings as well as the hoses before operating the equipment,
Check the hoses regularly; change them if they are damaged,
Never exceed the maximum working pressure (MWP) indicated on the hose.
USED PRODUCTS
Considering the wide variety of products that are available and can be used in our equipment it is
impossible to check and make recommendations for all chemical data,regarding the risks of
possible chemical attack and their long term chemical reaction
SAMES KREMLIN can not be held liable for :
compatibility of wetted parts,
risks to staff and the surroundings,
for worn or defective parts, for faulty equipment or units, or the qualitiy of final product.
It is the responsibility of the user to know and prevent any possible risks such as toxic vapours,
fires or explosions. He shall determine the risks of immediate reactions or pursuant to repeated
exposures of the staff,
SAMES KREMLIN shall not be liable for physical injuries, direct or indirect material damages
caused by the use of chemicals.

SAMES KREMLIN - 4 - N° : 578.001.130-UK-1804
2. HANDLING
Check the weight and the dimensions of the equipment
(  refer to 'Technical features' section of the instruction manual
If weight and dimensions are too important, the unloading must be carried out by means of a forklift or
any other appropriate means with a qualified personnal and in a clear horizontal area to prevent from
risks of damage injury or an accident.
The centre of gravity is not in the centre of the machine : carry out by hand a stability-test after having
lifted the whole at 10 cm / 3.937" maximum.
After the unloading, the handling of the whole (eg: elevator pump) is carried out by means of a pallet
truck taking the bottom part of the frame.
Remark : Each pump motor is fitted with a ring. The ring is designed for the hoisting of one
pump and can not be used for the handling of the complete assembly.
3. STORING
Storing before installation :
- Storing ambient temperature : 0 / +50 °C / 0 / +122°F
- Protect the whole against dust, water trickling, dampness and shocks.
Storing after installation :
- Operating temperature : +15 / +35 °C / +59 / +138.2° F
- Protect the whole against dust, water tricling, dampness and shocks.
4. INSTALLATION OF THE EQUIPMENT
The machine is installed on a stable horizontal floor (for eg a concrete flag).
The machine shall be made stable by the use of holding down bolts or by the use of other anchoring
methods, strong enough to prevent unintended bodily movement of the equipment.
To avoid risks caused by static electricity, the equipment as well as its components must
be grounded.
For the pumping equipments (pumps, pneumatic rams, frame…), a section wire of 2.5
mm² is fixed on the material. Use this wire to connect the material to “the general ground”.
In case of severe environments (mechanical protection of the wire of earthing insufficient,
vibrations, mobile material…) where function damages at the ground are probable, the user
have to replace the provided wire of 2.5 mm² by a device more adapted to its environment
(wire with a more important section, bonding strip, fixing by thimble with eyelet…).
The continuity of the ground must be controlled by a qualified electrician. If the continuity of
the ground is not ensured, check the terminal, the wire and the earthing point. Never use the
material without have solved this problem.
In the severe cases of environments (mechanical protection of the wire of earthing
insufficient, vibrations, mobile material…) where damages of the function put at the ground
are probable, the user will have to replace the wire of 2.5 mm² provided, by a device more
adapted to its environment (wire of more important section, bonding strip, fixing by thimble
with eyelet…),
The gun must be 'grounded' via a material hose or an air hose. In case of spraying by
means of a gun with cup, the air hose must be conductive,
The materials to be painted must also be grounded.
All the materials situated in the working area shall be grounded.

SAMES KREMLIN - 5 - N° : 578.001.130-UK-1804
Never store more than necessary inflammable materials inside the working area,
The materials must be stored into approved drums and grounded,
Use only grounded metals containers for the use of cleaning solvents,
Cardboard and paper are prohibited.
5. MARKING OF THE EQUIPMENT
Each equipment has a label plate with the name of the manufacturer, the equipment part number,
the interesting informations to use correctly the equipment (pressure, voltage,…) and sometimes
the above pictogram.
The equipment is designed with and consists of high quality materials and components which can
be re-used.
The 2012/19/UE European Directive covers all equipments with a crossed-out bin pictogram.
Please inform yourself about the collection systems for electric and electronic equipments.
Please act in accordance with local rules and do not dispose of old equipment with household
wastes. A correct disposal of old equipment will help prevent negative consequences for the
environment and health.

INSTRUCTION MANUAL
FLOWMAX® AIRMIX® PROPORTIONING PUMP
MODEL PU 2160 F
Manual : 2011 573.182.112
Date : 30/11/20 - Supersede : 4/11/08
Modif. : Update
TRANSLATION FROM THE ORIGINAL MANUAL
IMPORTANT : Before assembly and start-up, please read and clearly understand all the
documents relating to this equipment (professional use only).
THE PICTURES AND DRAWINGS ARE NON CONTRACTUAL. WE RESERVE THE RIGHT TO MAKE CHANGES WITHOUT
PRIOR NOTICE.
SAMES KREMLIN SAS
l
13, chemin de Malacher
38 240 - MEYLAN - France
 : 33 (0)4 76 41 60 60
www.sames-kremlin.com

SAMES KREMLIN Page 1 Manual : 573.182.112
INSTRUCTION MANUAL
FLOWMAX® AIRMIX® PROPORTIONING PUMP
MODEL PU 2160 F
CONTENTS
1. SAFETY........................................................................................................................................................ 2
2. TECHNICAL FEATURES............................................................................................................................. 3
3. OPERATING PRINCIPLE ............................................................................................................................ 4
4. INSTALLATION ........................................................................................................................................... 5
5. OPERATING ................................................................................................................................................ 6
6. ADJUSTMENTS........................................................................................................................................... 9
7. CHANGING MIX RATIO ............................................................................................................................ 10
8. SHUTDOWN AT THE END OF WORK ..................................................................................................... 10
9. DAILY CARE.............................................................................................................................................. 10
10. TROUBLESHOOTINGS ............................................................................................................................ 11
11. DISASSEMBLY.......................................................................................................................................... 12
12. ASSEMBLY INSTRUCTIONS.................................................................................................................... 15
ADDITIONAL DOCUMENTATIONS :
Spare parts
Two-component pump, model PU 2160 F Doc. 573.331.050
Bare proportioning pump Doc. 573.332.050
Motor Doc. 573.272.050
Mixing / flushing manifold Doc. 573.333.050

SAMES KREMLIN Page 2 Manual : 573.182.112
Dear Customer,
We thank you very much for purchasing our PU 2160 F Flowmax® Airmix® two-component pump.
You are the owner of one of the most reliable pumping system available on the market.
Special care has been taken during all designing and manufacturing process to make sure your
investment will provide full satisfaction.
To get the best result, safe and efficient operation of your equipment, we advice you to read and
make yourself familiar with this instruction and service manual. Indeed, the non-compliance with this
instructions and precautions stated in this manual could reduce the equipment working life, result in
operating trouble and create unsafe conditions.
1. SAFETY

GENERAL SAFETY INSTRUCTIONS
CAUTION : The equipment can be dangerous if you do not follow our
instructions concern
ing installation and servicing described in this
manual and in accordance with applicable European standards and local
national safety regulations.
Please carefully read all the instruction literature before operating your
equipment.
Only trained operators can use the equipment.
The foreman must ensure that the operator has understood the safety instructions for this equipment
as well as the instructions in the manuals for the different parts and accessories.
Read carefully all instruction manuals, label markings before operating the equipment.
Incorrect use may result in injury. This equipment is for professional use only. It must be used only for
what it has been designed for. Never modify the equipment. The parts and accessories supplied must
be regularly inspected. Defective or worn parts must be replaced.
Never exceed the equipment components' maximum working pressure.
Comply with regulations concerning safety, fire risks, electrical regulations in force in the country of
final destination of the material. Use only products or solvent compatible with the parts in contact with
the material (refer to data sheet of the material manufacturer).

Refer to 'Installation and safety instructions' document
(doc. 578.001.130-UK)

SPECIFIC SAFETY INSTRUCTIONS
Use only non-static quality air hose to connect the pump to the spray gun,
Ground the pump (use the connection on the pump),
The compressed air supply must not exceed 6 bar / 87 psi.
Make sure the lubricant in the cup of the fluid section is compatible,
Use the appropriate solvent for the material being sprayed to increase the equipment working
life.

SAMES KREMLIN Page 3 Manual : 573.182.112
2. TECHNICAL FEATURES
The PU 2160 F fixed ratio pump is used for applying two component material with one Airmix ® gun.
The proportioning pump is mounted on a cart and composed of :
- a mixer,
- a PRODUCT/SOLVENT selection assembly,
- a suction rod and a drain rod for BASE,
- a suction rod for the solvent,
- a gravity container and an hose for CATALYST.
Mix ratio .........................................................1/1, 2/1, 5/1, 10/1 (depending upon choice of CATA fluid
section)
Viscosity......................................................... 180 s CA4 maxi
Motor ............................................................. type 700-2
The BASE fluid section is an IntensiveTM version. The CATALYST fluid section is a FLOWMAX®
technology.
Mix ratio Delivery per cycle (cm3) Flow rate at
20 cycles
(l / US gal)
Pressure
ratio
Fluid
pressure at
6 bar / 87 psi
(bar / psi)
Fluid
pressure at
4 bar / 58 psi
(bar / psi)
A B
1/1 19 19 0.8 / 0.21 10 60 / 870 40 / 580
2/1 19 9,5 0.6 / 0.16 15 90 / 1305 60 / 870
5/1 19 3,8 0.5 / 0.13 18 108 / 1566 72 / 1044
10/1 19 1,9 0.4 / 0.10 20 120 / 1740 80 / 1160
Air supply pressure Minimum : 3 bar / 43.5 psi - Maximum : 6 bar / 87 psi
Air consumption of the proportioning
pump (Nm3/h)
1,2 x (mixed fluid flow rate in l/mn) x pump ratio x (motor air
pressure + 1 bar) x 60/1000
Wetted parts PU with 1/1, 2/1 & 5/1 ratio
BASE and CATA fluid section :stainless steel
CATA circuit : stainless steel
Mixer : stainless steel, treated steel and polyethylene
PU with 10/1 ratio
BASE fluid section : stainless steel
CATA fluid section : 316L stainless steel
CATA circuit : 316L stainless steel
Mixer : 316L stainless steel and polyethylene
Bellows : PTFE
Fittings Air inlet : F 3/8 BSP
Spraying air : M 1/4 NPS
Fluid outlet (manifold) : M 1/2 JIC
Overall weight 60 kg / 132 lb
Dimensions 110 x 55 x 50 cm
Maximum operating temperature 50° C / 122° F
Noise level (to 1m) 80 dB A (depending upon ISO 3746 standard)

SAMES KREMLIN Page 4 Manual : 573.182.112
3. OPERATING PRINCIPLE
HA
HB
BMP
S
A
AC
19
17
18
1314
11
12
98
15
20
This pump measures and mixes 2 components A and B to a single defined volume proportion (see
data sheet of the product).
The fluid sections HA and HB are coupled to an air motor MP. Their sizes have been calculated in
order that each delivers the components A and B to the predetermined proportion.
Fluid section HA draws and delivers the BASE A.
Fluid section HB draws and delivers the CATALYST B.
When pulling gun trigger (19), proportioning pump starts cycling and draws the BASE and the
CATALYST. Simultaneously, they are delivered in valves (11 and 12), check valves (13 and 14) and
are mixed in the static mixer (15). Then, they flow out completely mixed before passing through hose
(17) to the gun.
As soon as the trigger is released, the proportioning pump stops cycling :
The regulator (9) regulates the air pressure to the pump, thus regulating material pressure.
The regulator (8) regulates the atomizing air pressure to the gun.
Nota :
The valve (11) is a three-ways' valve :
- handle horizontally ⇒fluid circulation (priming stage),
- handle vertically ⇒fluid towards mixer (working stage, flushing stage).
The valve (12) is a color changer fitted with 2 fluid valves. These valves are piloted pneumatically
alternately, connecting the air tube in spiral on one or the other valve :
Left connection ⇒
fluid circulation (priming
stage)
Right connection ⇒fluid towards mixer (working
stage).
Nota : During the FLUSHING stage,
- the BASE fluid section draws solvent; that solvent is exhausted towards the manifold, the mixer and
the gun.
the BASE circuit and the mixed circuit will be flushed.
- the catalyst circulates. The CATALYST circuit is not flushed.

SAMES KREMLIN Page 5 Manual : 573.182.112
4. INSTALLATION
The pumps are designed to be installed in a spray booth.

DESCRIPTION OF THE LABEL
MARKING
Marking in accordance with the ATEX
regulation
SAMES KREMLIN
93240 STAINS FRANCE Name and address of the manufacturer
II 2 G II : group II 2: class 2
Surface equipment meant to an area where explosive atmospheres due to
gas, vapours, mists are liable to appear from time to time in usual operating.
G: gas
TYPE Pump version: PU 2160 F
RATIO Mixing ratio
SERIE - SERIAL Number given by SAMES KREMLIN
P air : 6 bar / 87 psi Air supply maximum pressure of the pump motor
P prod : xx bar / xx psi Maximum fluid pressure at the pump outlet

INSTALLATION DIAGRAM
HA
HB
B
MP
S
A
AC
B
A
Z1
Z2
Z2
1m
1m
1
2
A -
B -
1 -
2 -
Explosive
zone
zone 1 (Z1)
or zone 2
(Z2) :
spraybooth
Non-
explosive
area
PU 2160 F
pump
Airmix® gun
(+ nozzle,
from 04 to
09)

SAMES KREMLIN Page 6 Manual : 573.182.112

INSTALLATION
HA
HB
BMP
S
A
AC
19
17
18
1314
11
12
98
15
20
Interconnect hoses (18) and (17) between the pump and the AIRMIX ® gun :
The hose (18) should be static proof (green band). I.D. 7 mm / 9/32".
The hose (17) should be an AIRMIX ® one. I.D. 4,8 mm / 3/16" or 6,5 mm / 1/4".
Connect the pump air supply to the compressed air system with an hose - I.D. 10 mm / 3/8".
Nota : these hoses are not included in the equipment.
Choose an AIRMIX ® nozzle (size from 04 to 09 - refer to chart of nozzles in the gun instruction
manual) and install it on the gun (19).
The PU 2160F pump is fitted with an earth cable. Ground the pump.
Fill with 'T' lubricant or with the appropriate lubricant the BASE fluid section flange. Fill the cup to
the 3/4.
Unscrew the 2 air regulators (8 & 9), then supply the equipment with air (maximum P = 6 bar / 87
psi, clean air).
→
Do not install isolating valve on the CATA supply system (between the tank and
the FLOWMAX fluid section). It will damage the bellows.
→
Do not install a system that will act as a non return valve.
→
You must not create an overpressure in the CATA system.
5. OPERATING

LABEL
The label sticked on the pump explains the 3 operating stages of the pump : PRIMING -
WORKING - FLUSHING.
The 3 operating stages are selected :
- working the manifold valve (11) (→index A on the label),
- operating one of the valves of the color changer (12) (→index B on the label),
- working the valve (20) located at the base and solvent suction (→index S on the label).

SAMES KREMLIN Page 7 Manual : 573.182.112
Stages :
1 - Priming
2 - Working
3 - Partial
flushing
The label indicates also the air pressure adjustment on the motor of the pump.
: Low pressure
: Higher pressure

FIRST START UP
CAUTION : This pump has been checked and tested with water in our factory.
During the first start up, a flushing of the circuits with solvent is required
to ensure a good operating of this pump.
Be certain the gun trigger is released and hoses are properly interconnected.
Insert BASE drain rod and CATA hose into waste containers.
Insert suction rod of BASE fluid section into SOLVENT container.
Fill up with SOLVENT the CATALYST container.
Be certain the manifold hand levers are in the PRIMING position.
Adjust the black regulator 'Air motor' (9) between 0.5 and 2 bar / 7 and 29 psi.
Both components must flow freely from BASE drain rod and CATA hose into waste containers.
Once drained the circuits, insert the drain rod into the solvent container and the CATALYST hose
into the other container. Make the materials circulate until air bubbles are evacuated.
Unscrew the air regulator (9), then empty the solvent of the CATA container.
Prepare the materials :
Fill up a container with Material A (BASE),
Fill up the pump container (Maximum 10 liters / 2.6 US gal) with material B (CATALYST),
Fill up a container with Flushing Solvent S.
Insert BASE suction rod (Ø 16) into BASE container and the 'BASE' rod into a waste container.
Insert SOLVENT rod into solvent container.
Insert 'CATA' hose into a waste container.
PRIME (Stage 1) to evacuate solvent into fluid sections, then insert BASE drain rod into BASE
container and CATA hose into CATA container.

SAMES KREMLIN Page 8 Manual : 573.182.112

MATERIAL PRIMING (STAGE 1)
Move the valve (20) hand lever to supply the
pump with material A (BASE).
Move the valve (11) hand lever horizontally.
Connect the air tube on the hole on the far left
of the plate (⇒
opening of the CTM valve to
the container B).
Screw the black regulator until pump begins
to start up (pressure : from 1 to 2 bar / from
14.5 to 29 psi).
The base A is drawn then delivered by the
BASE fluid section. It passes through the
valve (11) of the manifold and goes back to
the container A.
The catalyst flows from container B, is drawn
by the CATA fluid section. It passes through
the valve (12) of the manifold and goes back
to the container B.
Leave the materials circulate for a few
minutes. When air bubbles are evacuated, the
priming is over.
B
S
A
1
20
11
12

WORKING (STAGE 2)
Leave the valve (20) hand lever in the same
position (the pump must be supplied with
materials A and B).
Position the valve (11) hand lever vertically.
Connect the air tube on the hole on the far
right of the plate (⇒opening of the CTM
valve towards the AR valve).
Screw the black
regulator 'Pump pressure'
until the pump begins to start up.
The base A and the cata B are drawn then
delivered by their respective fluid section.
Each material comes to the manifold and is
mixed at the outlet in the mixer.
Point and trigger the gun into a waste
receptacle.
When material flows out regularly, screw the
phosphorous regulator "Spraying air".
Adjust the 2 regulators to get a correct fan :
- adjust the material pressure with the black
regulator,
- adjust the spraying air with the
phosphorous regulator.
B
S
A
20
11
12
2

SAMES KREMLIN Page 9 Manual : 573.182.112

PARTIAL FLUSHING (STAGE 3)
If the working shutdown lasts longer than the
material "working life", carry out a PARTIAL
flushing.
The FLUSHING stage enables to flush the
BASE circuit and the mixed material.
Move the valve (20) hand lever to supply the
BASE fluid section with solvent.
Position the valve (11) hand lever vertically.
Connect the air tube on the hole on the far left
of the plate (opening of the CTM valve
towards the container B ⇒
circulation of the
catalyst).
Screw the black regulator 'Pump Pressure'
until pump begins to start (pressure : from 1
to 2 bar / from 14.5 to 29 psi).
The solvent S and the cata B are drawn and
delivered via their respective fluid section.
Each material comes to the manifold valves :
the CATA is sent to the container, the solvent
passes through the manifold, the mixer and
comes to the gun.
Remove aircap and tip from the gun and
clean them carefully.
Point and trigger the gun in
to a waster
receptacle.
When clean solvent flows out, the circuit is
flushed.
Leave the equipment until a next utilization
A
A
S
B
20
11
12
3
6. ADJUSTMENTS
TROUBLE CAUSE SOLUTION
Coating not thick enough Not enough material
Increase the material fluid
pressure using black knob.
Spray slower or closer to part
being painted.
Use the next higher nozzle
size.
Sags, runs
Too much material
Decrease the material
pressure using black knob.
Spray faster or farther from
part being painted.
Use the next smaller size.
Distorted spray fan Refer to gun instruction manual

SAMES KREMLIN Page 10 Manual : 573.182.112
7. CHANGING MIX RATIO
The PU 2160 features a fixed ratio proportioning system (ratio : 1/1, 2/1, 10/1 according to the choice
of the CATA fluid section).
To change the ratio, the CATALYST fluid section must be changed with a fluid section of a different
ratio (refer to PU 2160F spare parts' list).
8. SHUTDOWN AT THE END OF WORK

COMPLETE FLUSHING : ONLY FOR MATERIAL / COLOR CHANGE OR LONG DURATION
SHUTDOWN.
Carry out a partial flushing (refer to § 7).
Empty the CATALYST container - replace CATALYST with CLEAN solvent.
Insert SOLVENT suction rod into a container of CLEAN solvent.
Place the valve (11) hand lever vertically.
Connect the air tube in spiral on the far right of
the plate (⇒opening of the CTM valve towards
the AR valve).
Adjust the black regulator (9) to 2 or 3 bar / 29 or 43.5 psi.
Point the gun into a waste container and make the fluid flow out until you get solvent.
Remove the aircap and the nozzle and clean them.
Remove and clean the mixer (15).
Remove and clean the CATA tank screen after having emptied the tank content.
 To get a perfect flushing, repeat that procedure twice using some CLEAN solvent.
Reinstall the aircap and the nozzle onto the gun.
Shut off the main air supply.
Leave the pump filled with clean solvent.
9. DAILY CARE

SPRAY GUN
Comply with the usual instructions of spray gun servicing (refer to spray gun instruction manual).

PUMP
Make sure the wetting cup of the BASE fluid section is filled up with T lubricant. Fill if necessary
(level : 3/4 of the cup).
Regularly change the lubricant (this lubricant will normally be coloured by the paint). Make sure the
wetting cup is clean and regularly clean it with solvent after having drained the lubricant.
Make sure the suction strainers and rods are clean and in good condition.
Check the hoses.
Flush the pump as often as necessary.
Never inject oil into the compressed air supply.
The CATALYST tank is fitted with a screen. Clean that screen regularly or change it, if necessary
(filtration size : 50 MESH)
When stopping the pump, always leave it filled up with material.
For a short duration, if the flushing has not been carried out, leave the pump filled up with
material.
For a long duration, after flushing the pump, leave it filled up with solvent.

SAMES KREMLIN Page 11 Manual : 573.182.112
Before cleaning or removing a component of the equipment, you must :
1 - stop the pump compressed air supply,
2 - place the manifold valves in 'circulation' position,
3 - trigger the gun to depressurize the hoses.
10.TROUBLESHOOTINGS
HA
HB
B
MP
S
A
AC
19
17
18
1314
11
12
98
15
20

THE PUMP DOES NOT OPERATE
Check :
♦It is supplied with air,
♦The valves (11 & 12)
are in 'WORK'
position,
♦The gauge (9) indicates a pressure
between 2 and 6 bar / 29 to 87 psi,
♦The mixer (15) and the hose (17) are not
clogged,
♦The gun filter, if there is one, is not clogged,
♦The gun nozzle is not clogged.

RATIO CHECKING
From time to time, you must check the ratio :
1 - The CATALYST container is translucent. Mark on the CATALYST level, then add a CATALYST
volume (for example 1 liter / 0.26 US gal),
2 - Determine the volume of the BASE,
3 - Operate the pump until the volume of catalyst falls to its initial level,
4 - Determine the volume of BASE used. In this case, the ratio is :
Volume of BASE used (in liters) = Material mix ratio *
1 liter
*Nota : The reading of the proportioning ratio is highly sensitive to the viscosity of the
materials.

SAMES KREMLIN Page 12 Manual : 573.182.112
11.DISASSEMBLY
WARNING !
Before any intervention on the pump :
- shut off the compressed air supply,
- place the manifold valves in 'circulation' position,
- trigger the gun to depressurize the circuits,
- empty the CATALYST container.
BASE FLUID SECTION - HA (Refer to Doc. 573.332.050)
To disassemble the BASE fluid section (HA), remove the lower part of the pump [the
CATALYST fluid section (HB) and the suction kit (11)] removing the nuts (6), the tie-rods (4)
and the fixing plate (9).

SUCTION VALVE
Unscrew the suction valve body
(19).
The ball (22) is secured on the
seat (20) by means of a stop ring
(23).
Reinstall the suction valve
assembly and change the seal
(21).

EXHAUST VALVE
Unscrew the cylinder (17).
Unscrew the seat (26) by holding
valve support (29) to remove ball
(27).
Check if cup seal is not damaged
(28), change it if necessary.
Reinstall the parts in the reverse
order and tighten the seat (26)
completely on the valve support
(29). Change cylinder seal (18).

CARTRIDGE
To
separate BASE fluid section
from air motor, remove tie-rods
(1), pin (3) and connecting pin (2).
Remove circlips (13) located in
the fluid section flange (32) and
pull cartridge (14) downwards to
remove it.
Install a new cartridge (12).
Reinstall in the reverse order. Be
careful not to damage the seal
when inserting piston-rod (30) into
cartridge (14).