Kremlin-Rexson AIRLESS FLOWMAX 40.130 F2 User manual

KREMLIN REXSON N° : 578.156.110-UK-1202
AIRLESS FLOWMAX
PUMPS
40.130 F2
65.130 F2
Disassembly / Reassembly
TRANSLATION OF 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.
KREMLIN - REXSON
l
150, avenue de Stalingrad
93 245 - STAINS CEDEX – France
 : 33 (0)1 49 40 25 25 Fax : [phone]
www.kremlin-rexson.com

KREMLIN REXSON - 1 - N° : 578.156.110-UK-1202
CAUTION :
Before any action on the pump, shut off the compressed air supply and
depressurize the system.
The pump is manufactured under the ATEX agreement and can not be modified.
KREMLIN REXSON will not be held responsible for any failure to comply with that instruction.
FLUID MOTOR OR AIR MOTOR REPLACEMENT (REFER TO DOC. 573.407.050 & 573.410.050)
Guards (air motor cover, coupling shields, housings …) have been designed for
safe use of the equipment.
The manufacturer will not be held responsible for bodily injury or failure and / or
damage to property due to removal or partial removal of the guards
To remove a component of the pump :
- Disassemble all the accessories of the pump (rods, filter), if it necessary.
- Put aside the pump, if it is necessary (the pump is fitted with an hoisting ring).
Before removing the B sub-assembly or the A
sub-assembly, you must remove the connecting
rod (41). For that :
- Unscrew the nut fitting (38) and the screws (43 &
45),
- Remove the connecting rod (41).
The fluid section of the pump consists of 2
sub-assemblies : 
- the upper part (bellows suction
sub-assembly : A) 
- the lower part (fluid sub-assembly :
B)
This sub-assembly is more frequently
service than the A sub-assembly.


KREMLIN REXSON - 2 - N° : 578.156.110-UK-1202
DISASSEMBLY / REASSEMBLY OF THE FLUID SECTION
Guards (air motor cover, coupling shields, housings …) have been designed for
safe use of the equipment.
The manufacturer will not be held responsible for bodily injury or failure and / or
damage to property due to removal or partial removal of the guards
DISASSEMBLY / ASSEMBLY OF THE FLUID SUB-ASSEMBLY (B)
Nota : The suction valve, the cylinder, the exhaust valve and the upper GT-seal are dismounted and
change without needing to separate the fluid sub-assembly (B) from the suction sub-assembly (A).
SUCTION VALVE (30)
Disassembly
Unscrew the suction valve (30).
Nota : If the cylinder (21) remains attached to the
suction valve, unscrew both parts, then hold
cylinder (21) by inserting a rod into the cylinder
holes designed for this purpose.
The ball (32) is secured on the valve by means
of a circlips (33).
Clean the parts with the appropriate cleaning
solvent.
Assembly
Reinstall the ball (32) and the circlips (33) on the
suction valve body (31).
Change the seal (13). Lubricate it.
Lubricate the threading of the valve body.
Reinstall valve assembly (30) on the cylinder
(21).
CYLINDER (21)
In order to make easier the disassembly, a hole
is drilled in the cylinder (21) at each end.
Depending on the part that it is unscrewed first,
insert a rod into one of these holes to unscrew
the other part.
When reassemblying, make sure the two seals
(13) are installed. Lubricate them.
Lubricate the inside of the cylinder (grease,
type A1) and the tappings to prevent from
damaging the mobile packing (grease, type A2)
(refer to assembly instructions §).

KREMLIN REXSON - 3 - N° : 578.156.110-UK-1202
EXHAUST VALVE (29) AND MOBILE PACKING (23)
Disassembly
Unscrew the cylinder (21) and pull it downwards.
Unscrew the exhaust valve (29) with a impact
wrench (socket of 46) by holding the piston (22).
Remove the ball (25), the ring (34) and the
mobile packing (GT seal - 23).
Clean the parts.
Assembly
Install a new seal (23). Lubricate it.
Comply with the GT seal (23) installation
order.
Install the ball (25), the ring (34) on the exhaust
valve (29).
Lubricate the threading of the exhaust valve (grease, type A2).
Screw the whole on the piston lower part (22).
DISASSEMBLY / ASSEMBLY OF THE BELLOWS SUCTION SUB-ASSEMBLY (A)
The disassembling of the upper thightness seal and of the bellows requires to separate the
the fluid sub-assembly (B) from the suction sub-assembly (A)
SEPARATION PROCEDURE
Disassemble the cylinder (21). You can see the
fluid section piston (22).
You must place the piston downwards.
install an air pressure (from 0.2 to 0.5 bar / from
2.9 to 7.2 psi) on the air motor to make the
piston (22) get down. When the piston is at its
lower point, close the air inlet valve to prevent
the piston from getting up.
Remove the 3 nuts (11), the washers (12).
Pull the suction flange (1) downwards, you can
see the skirt (6).
Nota: The cylinder (2) must keep assemble with
the suction bearing (3).
Unscrew slightly the 3 screws (9) to give play on
the bellows (5).
Unscrew the skirt (6) (tools : 41 mm / 1.6"
wrench).
Nota : il est possible de démonter un des 3
tirants (7) de la pompe pour accéder, plus
facilement, à la jupe.
Nota :To make easier the disassembly of the
skirt, you can remove one of the 3 pump tie-
rods (7).
Caution : the skirt must be visible.
By means of the 2 wrenches, to separate the
piston (22) from the motor rod (40M) by using
the flats on the motor rod and those on the base
of the piston
A
B
7
1
22
21
20
5
6
40M
11&12
2
3
9
30
27
23 29 34

KREMLIN REXSON - 4 - N° : 578.156.110-UK-1202
COUPLING PROCEDURE
Change the seals (8 & 24) and lubricate them.
Clean the threading of the motor rod (40M) and the tapping of the pump piston (22).
Make the air motor rod get down (see the previous paragraph) .
Apply a light coating glue to the threading of the motor rod (Loctite 222).
Place the exhaust flange-fluid section piston assembly.
Screw the motor rod into the fluid section.
Apply a light coating of glue to the pump piston threading (Loctite 577).
Pull the skirt (6) downwards, then screw it on the fluid section piston (22).
(tool : 41 mm / 1.6" wrench).
Reinstall the tie-rod (7) if you removed it.
Reinstall the suction flange (1).
Tighten the 3 screws (9).
Place the 3 washers and tighten the nuts (11).
Reinstall the lower part of the pump (cylinder, suction valve, suction rod,…) in the reverse order of
the disassembly sequence, as explained previously.
Detail of the skirt (6) assembly
(6) on the piston (22)
6
1
22

KREMLIN REXSON - 5 - N° : 578.156.110-UK-1202
UPPER TIGHTNESS SEAL (27)
Disassembly
Unscrew the 8 screws (26)
Separate the fluid sub-assembly (A) from the suction
sub-assembly (B)
Remove the upper ring (35).
Remove the GT seal (27) by pulling the exhaust
flange (20) downwards.
Remove the o-ring seals (8 & 24) which are on the
suction flange.
Assembly
Place the GT-seal (27) in the exhaust flange (20)
after having lubricated it.
Comply with the GT seal (27) installation order.
DETAIL DRAWING
Place the upper part of the piston (22) on the cone shapped tool (refer to
above drawing).
Grease the cone shapped tool.
Slide the piston-cone shapped tool into the exhaust flange (20), from
downwards to upwards.
Slide the GT seal on the whole (the tool prevents from damaging the seal
when assembling the piston).
Remove the tool when it is above the flange (20).
Install the upper ring (35).
Change the seal (8) and tighten the 8 screws (26)
Couple the fluid sub-assembly (B) with the suction sub-assembly (A).
BELLOWS
This operation must be done after the separation of the lower part from the upper part of the fluid
section and after the dismounting of the upper thightness seal.
In the work table, prepare assembly, which consists of fluid section piston-exhaust flange while
following the procedure of the upper thightness seal (27).
Disassembly
Remove the bearing (3) from the cylinder (2).
Separate the suction bearing (3) from the motor by removing the screws (9).
Slide, then put aside the bellows-skirt-flange assembly.
Remove the bellows flange (4) to take off the upper part of the bellows.
Dismount the skirt (6).
27 22 35
20

KREMLIN REXSON - 6 - N° : 578.156.110-UK-1202
Assembly
To prepare an assembly,which consists of bellows-skirt-flange, you must :
- Install a new bellows (5) into the bellows flange (4).
- Change the seal (13).
Lubricate the seal (13) and the flange (4) (grease, type A1).
- Insert the assembly in the bearing (3).
- When installing the bellows, push it into skirt (6) firmly.
- Install the upper bellows flange (14).
Slide the bellows-skirt-flange assembly along the air motor rod.
Orientate it and tighten it on the air motor base by means of the 3 screws (9).
Nota :To make easier the assembly, you can remove one of the 3 pump tie-rods (7).
Couple the fluid sub-assembly (B) with the suction sub-assembly (A).

KREMLIN REXSON - 7 - N° : 578.156.110-UK-1202
AIR MOTOR
MOTOR REVERSING BLOCK
Guards (air motor cover, coupling shields, housings …) have been designed for
safe use of the equipment.
The manufacturer will not be held responsible for bodily injury or failure and / or
damage to property due to removal or partial removal of the guards
Disassemble the air motor cover (6) by removing the nut (4).
Dissociate the female yoke (27) from the reversing block lever
(9).
Dismount the reversing -block by removing the screws (28).
Reinstall the new reversing-block in the reverse order of the
disassembly sequence.
CAUTION : the number of spirals must equally be
distributed on each fastening parts in order to get the
above dimension.
31.85 mm ±0.5

KREMLIN REXSON - 8 - N° : 578.156.110-UK-1202
Before reassemblying the different components :
-Clean the parts with the appropriate cleaning solvent.
-Install new seals if it is necessary, after having lubricated them with PTFE grease.
-Lubricate the piston and the inside of the cylinder to prevent from damaging the seals.
-Install new parts if it is necessary.
DEGREES OF WEAR
The wetted parts in contact with the material are subject to wear with time. It depends, of course, on the
rates and duration of pump operating; also on the material handled.
Under normal operating and servicing conditions, with standard filled material not including foreign
matters or chemically aggressive, the average working life can be estimated as :
-1 million strokes for the tightness seals.
-10 millions strokes for the bellows.

KREMLIN REXSON - 9 - N° : 578.156.110-UK-1202
ASSEMBLY INSTRUCTIONS
Index Instruction Description Part number
A 1 PTFE grease 'TECHNILUB' grease (10 ml) 560.440.101
A 2 Graphite grease Graphite grease box
(1 kg / 2.204 lb) 560.420.005
C 1 Medium strength
Aneorobic Pipe sealant Loctite 577
C 2 Low strength
Aneorobic Adhesive Loctite 222
C 2
C 1
40M
22
6
8
27
A 1
A 1
1
35
20