SAMES KREMLIN REXSON 4B6000 User manual

4 BALL PUMP
6000 cm3
Pump REXSON 4B6000
User Manual 582203110
2021-10-08
Index A
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

Any communication or reproduction of this document, in any 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

3
Contents
Evolution table of the document................................................................................................ 5
Additional Documentations......................................................................................................... 5
Guarantee ..................................................................................................................................... 6
1Declaration of conformity ............................................................................................................ 7
2Safety instructions.......................................................................................................................... 8
2.1 Personal safety ............................................................................................................................8
Overview ........................................................................................................................................ 8
Meaning of the pictograms......................................................................................................... 9
Security devices .......................................................................................................................... 10
Danger of pressure...................................................................................................................... 10
Injection hazards ......................................................................................................................... 11
Fire hazards, explosion, electric arc, static electricity ............................................................ 11
Toxic products hazards............................................................................................................... 12
2.2 Integrity of the material ...........................................................................................................13
Material recommendations ....................................................................................................... 13
Pump............................................................................................................................................. 13
Tubing ........................................................................................................................................... 13
Products implemented............................................................................................................... 14
3Environment ................................................................................................................................. 15
4Available configurations ............................................................................................................ 17
4.1 Rexson parts number of High viscosity pumps ....................................................................17
4.2 Table 1 Fluid section-Air motor selection..............................................................................18
4.3 Table 2 Fluid section – In / Out & Material selection..........................................................18
4.4 Table 3 Seals pack selection...................................................................................................19
5Identification ................................................................................................................................ 20
5.1 Description of the marking of the plate ...............................................................................20
5.2 Correspondence table New part numbers / Significant designations ..........................22
5.3 Correspondence table Existant part numbers / Significant designations .....................23
6Technical characteristics ........................................................................................................... 24
6.1 General characteristics ...........................................................................................................24
6.2 Wall bracket (accessory) ........................................................................................................25
Dimensions ................................................................................................................................... 25
6.3 Principle of operation...............................................................................................................26
Expected use ............................................................................................................................... 26
Functional description ................................................................................................................ 26
7Installation .................................................................................................................................... 28
7.1 Handling......................................................................................................................................28
7.2 Connections subsets ................................................................................................................28
7.2.1 Fluid supply connection ............................................................................................. 28
7.2.2 Air supply connection................................................................................................. 29
7.3 Storage........................................................................................................................................29

4
8Commissioning ............................................................................................................................ 30
Pump............................................................................................................................................. 30
Motor ............................................................................................................................................ 30
9Use of the product....................................................................................................................... 31
9.1 User settings................................................................................................................................31
Cup ............................................................................................................................................... 31
Tightening of the wet cup .......................................................................................................... 31
Tightening procedure ................................................................................................................. 31
9.2 Safety in production.................................................................................................................32
9.3 Start up........................................................................................................................................32
9.4 Shutdown procedure ...............................................................................................................33
Pump............................................................................................................................................. 33
9.5 Diagnostic help / Troubleshooting guide.............................................................................34
Possible symptoms of faults / Causes of faults / Remedies to apply .................................... 34
10 Maintenance ........................................................................................................................... 36
10.1 Preventive maintenance plan ...............................................................................................37
Fluid section ................................................................................................................................. 37
10.2 General preconisation maintenance...................................................................................39
11 Disassembly / Reassembly operation .................................................................................. 40
Greases and thread lockers designations ............................................................................... 40
Disassembly of the fluid section................................................................................................. 42
Cartridge ...................................................................................................................................... 42
Lower and upper valves............................................................................................................. 43
Piston assembly............................................................................................................................ 43
Reassembly fluid section ............................................................................................................ 44
12 Spare parts ............................................................................................................................... 45
Recommended Seals pack ....................................................................................................... 47
Accessories .................................................................................................................................. 48
Seals pack composition: 01 and 02 .......................................................................................... 49
Seals pack composition: 03 ....................................................................................................... 50

5
Evolution table of the
document
Recording revisions
Editor
Object
Revision
Date
Modified by
SEGUIN 4 Ball fluid section 6000 cm3
REXSON 4B6000
A 08/26/2021
Dear customer, you have just purchased your new equipment 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 Documentations
Documentation Reference
Air Motor 7200 582144110
Air Motor 9200 582145110
IMPORTANT:Before assembly and start-up, please read and
clearly understand all the documents relating to this equipment
(professional use only).

6
Guarantee
We reserve the right to make any changes or improvements even after
receipt of an order without being able to attribute a non-compliance
to the descriptions contained in the instruction manuals and selection
guides.
Our equipment is checked and tested in our workshops before
shipment.
To be valid, any complaint concerning a material will have to be
formulated to us in writing within 10 days of the delivery.
SAMES KREMLIN equipment, equipped with its original identification
plates, has a one-year warranty or 1800H of operation (in the first term
reaches) from the date of ex-factory against any defect of material or
defect of it is up to us to see and appreciate.
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 be charged to us. The
costs of return to our workshops are the responsibility of the customer.
An intervention can be carried out on site at the customer's request.
In this case, the transportation and accommodation costs of the
technician (s) will remain the responsibility of the applicant.
Any changes made to our equipment without our consent will void the
warranty.
Our guarantee is limited to that of the suppliers of materials which enter
in the composition of our sets.

Declaration of conformity
7
1Declaration of conformity
Refer to the existing declaration delivered with the
product.

Safety instructions
8
2Safety instructions
2.1 Personal safety
Overview
Read all operating instructions and device labels carefully
before putting the equipment into service.
Personnel using this equipment must have been trained in its use.
The workshop manager must ensure that the operators have fully
understood all the instructions and safety rules of this equipment and
other elements and accessories of the installation.
Misuse or operation can 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.
Always respect the laws in force regarding security, fire, electricity of
the destination country of the equipment.
Only use products or solvents that are compatible with the parts in
contact with the product (see product manufacturer's technical data
sheet).

Safety instructions
9
Meaning of the pictograms
Danger: pinching,
crushing
Danger: moving
parts
Danger: high
pressure
Risks of product
emanation
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

Safety instructions
10
Security devices
Attention
Guards (motor cover, coupling guard, housings, ...)
are set up for safe use of the equipment.
The manufacturer cannot be held responsible for
any bodily injury as well as failures and / or damage
to the equipment resulting from the destruction,
the occultation or the total or partial removal of
the protectors.
Never exceed the maximum working pressures of
the equipment 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 material pressure can be relieved (after shutting off air motor
and decompressing it) before any intervention on the equipment.
These valves should remain closed for air and open for the material
during the procedure.

Safety instructions
11
Injection hazards
"HIGH PRESSURE" technology requires the utmost care.
Operation can cause dangerous leaks. There is a risk of product
injection into exposed parts of the body, which can lead to serious
injury and the risk of amputation:
An injection of product into the skin or other parts
of the body (eyes, fingers ...) must be treated
urgently by appropriate medical care.
Do not look at the gun nozzle when it is under
pressure.
Never point the gun nozzle at another person.
Never attempt to stop the jet with the body (hands,
fingers ...) or with rags or similar.
Fire hazards, explosion,
electric arc, static
electricity
Improper grounding, 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 electrical switches in the presence
of vapors or during removal,
Immediately stop the application in the presence
of arcs,
Store all liquids outside the work areas.
Use products whose flash point is as high as possible
to avoid any risk of formation of flammable gases
and vapors (consult the product safety data
sheets).
To equip the drums with a lid to reduce the diffusion
of gases and vapors in the cabin.
It is forbidden to pump explosive materials

Safety instructions
12
Toxic products hazards
Toxic products or vapors can cause serious injury through contact with
the body, in the eyes, under the skin, but also by ingestion or inhalation.
It is imperative:
To know the type of product used and the dangers
it represents,
Store the products to be used in appropriate areas,
Contain the product used in 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 of
aluminum or zinc is prohibited.
Failure to follow these instructions exposes the user to the
risk of explosion resulting in serious injury or death.

Safety instructions
13
2.2 Integrity of the material
Material recommendations
Protectors are put in place for safe use of the equipment.
The manufacturer cannot be held responsible in case of:
Bodily injury.
As well as breakdowns and / or damage to the
equipment resulting from the destruction, the misuse or
the total or partial withdrawal of the protectors.
Pump
It is imperative to be aware of the compatibility of the motors and
pumps before coupling them together as well as the special safety
instructions. These instructions can be found in the instructions manual
of the pump.
The air 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.
Never subject hoses being produced to temperatures
above 80°C or below 0°C.
Do not use hoses to pull or move equipment.
Tighten all connections and hoses and couplings before
operating equipment.
Check hoses regularly and replace if damaged.
Never exceed the maximum working pressure (MWP)
stated on the hose.
When fitting the hoses and the gun: PPE must be worn.
Tighten to full stop (hoses + gun).

Safety instructions
14
Products implemented
Given the diversity of the products implemented by the users and the
impossibility of listing all the characteristics of the chemical substances,
their interactions and their evolution over time SAMES KREMLIN can
not be held responsible:
The poor compatibility of materials in contact.
Inherent 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 declines any responsibility, in case of:
Bodily or psychic injuries.
Direct or indirect material damage due to the use
of chemical substances.

Environment
15
3Environment
The equipment must be installed on a horizontal, stable and flat ground
(eg concrete slab).
The non-mobile equipment must be fixed to their support by suitable
fixing devices (spit, screws, bolts, ...) to ensure their stability during their
use.
To avoid risks due to static electricity, the equipment and its
components must be grounded.
In combination with a pneumatic motor, the
hydraulics 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 in approved
containers and grounded.
Use only grounded metal buckets for the use of
rinse solvents.
Cartons and papers are to be banned. Indeed,
they are very bad conductors, even insulators.

Environment
16
Material marking
Each device is equipped with an identification plate with the name
of the manufacturer, the reference of the device, important
information for the use of the device (pressure, power, ...) and
sometimes against the pictogram shown below.
The equipment is 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 device
will help prevent adverse effects on the environment and human
health.

Available configurations
17
4Available configurations
4.1 Rexson parts number of High viscosity pumps
Presentation of the pump REXSON 4B6000
A high flow pump with very low pulsation dedicated to paint circulation
systems up to 54 liters per minute at 9 cycles/minute two different air
motors to allow you to cover pressures from 10 to 30 bar.
Different configurations are available.
Significant designation
Ex :
4B
R E X
6000
-

-

-

-

Technology
Ball pump 4B
Air Motor
None : XX
Motor 7200 : 72
Motor 9200 : 92
Refer table 1
Material of construction
SS : Stainless steel
Refer table 2
In / out
G4: GAZ 2” Female
M2: M 52x200
Refer table 2
Seal pack
PE (FKM) : 01
PTFE + Leather (EPDM) : 02
PE + Leather (FKM): 03
Refer table 3
Product Family
REXSON Pump : REX
4B
R E X
6000
-
72
-
SS
-
G4
-
01
Cycle volume
4 digits in cm3

Available configurations
18
4.2 Table 1 Fluid section-Air motor selection
Available motors
Pressure
ratio
Maximum air inlet
pressure
Maximum outlet
fluid pressure
Documentation
reference
bar
psi
bar
psi
XX
NONE
-
-
-
-
72
MOTOR 7200
3 : 1
6
100
18
261
582144110
92
MOTOR 9200
5 : 1
6
100
30
435
582145110
4.3 Table 2 Fluid section – In / Out & Material selection
Available in / out
Available material
SS
Stainless steel
G4 2’’ F BSPP 
M2 M 52x200 
4B
R E X
6000
-

-

-

-

4B
R E X
6000
-

-

-

-


Available configurations
19
4.4 Table 3 Seals pack selection
Available seals packing
Static seals "O"-rings
Cup seals
packing
Piston seals
packing
01
PE FKM PE UHMW PE
02
PTFE + Leather EPDM PTFE and Leather UHMW PE
03
PE + Leather FKM PE and Leather UHMW PE
PTFE=Polytetrafluorothylene (Teflon like properties) / PTFEG=PTFE + Graphite (impregnated)
PE-Polyethylen High Density (PEHD) / FKM=Flouroelastomer (Viton like properties)
UHMW PE= Ultra High Moleecular Weight Polyethylen
PU=Polyurethane / PTFEV=PTFE + Glass (impregnated)
FEP=Encapsulated O-Ring (Teflon like properties over Viton or Silicone)
4B
R E X
6000
-

-

-

-


Identification
20
5Identification
5.1 Description of the marking of the plate
Principles
This equipment complies with the following provisions:
Machinery Directive (2006/42 / EC),
Low 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).