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Trebor MAGNUM 610R, Operation & Maintenance Manual, Page: 22 / 24

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PAGE 22 

MAGNUM 610R PUMP OPERATION / MAINTENANCE MANUAL 

Erratic Cycling 

Cause: 

Solution: 

 

 

Leaking shuttle cap. 

 

 

Tighten; or remove and wrap with PTFE thread tape prior 
to tightening. 

 

 

Fluid supply line restricted (cavitation). 

 

 

Reduce fluid restriction. 

Reduce distance, height of suction head. 

Increase diameter of suction supply line (reduces 
restriction). 

 

 

Fluid supply line pressure. 

 

 

Adjust check muffler assembly (see 0). 

 

 

Pilot valve not seating. 

 

 

Check pilot valve function and seal. 

Additional TFE thread tape on pilot valve threads. 

 

 

Pilot valve transfer O-rings leaking. 

 

 

Check diaphragm hole alignment.  Replace O-ring seals. 

 

 

Check ball(s) not seating. 

 

 

Replace check balls and O-rings. 

Summary of Contents for MAGNUM 610R

Page 1: ... top of product PATENTS U S 09642426 U S 06106246 U S 05971402 U S 05370507 1 29 2014 M610R B Phone 800 669 1303 or 801 561 0303 Fax 801 255 2312 e mail treborservice idexcorp com MAGNUM 610R PUMP Operation Maintenance Manual ...

Page 2: ... TEMPERATURE OPERATION 8 3 2 PERFORMANCE CHARTS 8 4 MAINTENANCE 10 4 1 PREVENTIVE MAINTENANCE SCHEDULE 10 4 1 a Preventive Maintenance Record 12 4 2 RECOMMENDED SPARE PARTS 13 4 3 TOOLS 13 4 4 PARTS ILLUSTRATION 14 4 5 PARTS LIST 15 4 6 CLEAN UP 15 4 7 DISASSEMBLY 15 4 7 a Body Disassembly 16 4 7 b Head Disassembly 16 4 8 ASSEMBLY 17 4 8 a Head Assemblies 17 4 8 b Body Assembly 17 4 8 c Final Asse...

Page 3: ...Apply 42 in lbs of torque to each slave side bolt while holding the master side bolt stationary A star pattern is advised a The master side is the left side of the pump if you are looking at the fluid ports 3 Replace tie bolt caps 1 3 UTILITIES HOOK UP It is recommended that the pump be installed no more than 15 from level to maintain its self priming ability and pumping efficiency This pump mount...

Page 4: ...tings 4 Normal pump operation requires suction negative fluid head supply Figure 1 1 ATTENTION The pump should be operated with clean dry air or nitrogen Particulate water and oils in the air supply can damage the pump NOTE 1 It is recommended that a filter be placed on the discharge side of the pump ...

Page 5: ... that can enter into the pump s internal air circuit components while the pump air supply is off A common cause of shuttle and pilot valve failures 1 4 b Adjustment The Check Muffler is preset at the factory to a setting that makes the pump Dead Cycle at a slow constant rate with the fluid discharge port closed and the pump air supply at 45 psig This setting also allows the pump to operate with ap...

Page 6: ...NCE MANUAL Figure 1 2 Turn adjustment screw clockwise CW to increase backpressure Turn adjustment screw counter clockwise CCW to decrease backpressure NOTE Loosen locking nut prior to making adjustment then re tighten nut to maintain adjustment ...

Page 7: ...plumbing Available Options A PFA Weldable pipe 1 2 B Flare style tube adapter 1 2 3 4 C PFA tube stub out 3 4 Figure 2 1 2 2 FLUID FITTINGS SURGE SUPPRESSOR HOOK UP Surge Suppressor Assembled Height IN CM SS75 12 29 31 21 SS85 14 82 37 65 SS40 12 37 31 43 Figure 2 2 NOTE See Surge Suppressor Operation Manual for detailed installation instructions A B C ...

Page 8: ... fittings should be placed in an enclosure 3 1 HIGH TEMPERATURE OPERATION Pump operation at temperatures above 60 C requires periodic tightening of the tie bolt nuts The frequency of this procedure is best established by the user Refer to Section 4 on Maintenance 3 2 PERFORMANCE CHARTS Pumping capacity is a function of air supply pressure and volume suction head suction line restrictions discharge...

Page 9: ...MAGNUM 610R PUMP OPERATION MAINTENANCE MANUAL PAGE 9 Figure 3 1 Pressure Capacity Chart NOTE Test information is based on specific conditions and limited sampling Use for general reference only ...

Page 10: ...pumps are to be shipped freight prepaid with a valid Purchase Order for the cost of rebuild service Please contact Trebor International prior to returning your pump to obtain an RMA Number and Pump Return Data Sheet to ensure proper safety precautions Each pump will be evaluated and repaired within 5 working days of the receipt of pump at Trebor facility 4 1 PREVENTIVE MAINTENANCE SCHEDULE The fol...

Page 11: ...me Operating Conditions below Required if operating temperature exceeds 60 C or thermal cycling occurs Extreme Operating Conditions Install 30 Days 3 Months 6 Months 9 Months 12 Months 15 Months 18 Months 21 Months 24 Months Tie Bolt Torque 42 lb in I I I I I I I I I I Detent 60 CPM I Shuttle Spool and Detent 60 CPM R Check Balls and O Rings R R R R Shaft Seal and Shaft R R R R Diaphragms and Main...

Page 12: ...__ ________________________________________ Date ________ Tech _____ Notes ________________________________________ ________________________________________ Date ________ Tech _____ Notes ________________________________________ ________________________________________ Date ________ Tech _____ Notes ________________________________________ ________________________________________ Date ________ Tec...

Page 13: ...Ball 98001976 2 Shaft Seal 98002331 2 O Ring 98002332 2 O Ring 98002334 4 O Ring PTFE AM084 2 Check Cap Seal C0135 1 Check Muffler 4 3 TOOLS The following tool kit is recommended as standard service equipment KT610R 00 A Tool Kit which includes Part No Qty Description 98001225 2 3 8 Nut Driver 98001226 1 1 2 Nut Driver 98001230 1 5 32 Allen Wrench 98002327 1 Tool Case 98003225 1 3 8 Socket 9800330...

Page 14: ...PAGE 14 MAGNUM 610R PUMP OPERATION MAINTENANCE MANUAL 4 4 PARTS ILLUSTRATION ...

Page 15: ... 1 Detent 1 2 Acetal SS 27 11001210 1 Shuttle Assembly 1 2 SS410 Buna 28 C0135 1 Check Muffler Assembly 2 PP NPRN 29 98001109 12 Tie Bolt Cap 2 PU 30 98002338 6 Nut Flanged SS18 8 31 1610D0005 01 1 Master Head PP 4 6 CLEAN UP The pump fluid cavities may be flushed clean by cycling with the suction IN and discharge OUT lines connected to a DI water flushing or rinsing tank Flushing using an externa...

Page 16: ...k bore caps using 3 4 pin tool and remove seals Remove sleeves with sleeve removal tool check balls and O rings Unthread one push plate from the shaft Remove remaining push plate and shaft from body Unthread second push plate from shaft Remove shaft seals from the shaft bore taking care not to damage the shaft bore or shaft seal grooves Do not re use shaft seals 4 7 b Head Disassembly Remove the s...

Page 17: ...ol or sleeve Check the shuttle assembly making sure it has notched O rings on each end See Section 4 4 for shuttle detail Insert shuttle sleeve into the shuttle bore Insert shuttle spool Insert detent Install shuttle cap with 2 wraps of TFE tape 4 8 b Body Assembly NOTE For easy installation check sleeves that fit too tightly should be placed in a freezer prior to assembly to assist insertion Body...

Page 18: ...bust contact point for the O rings Repeat insertion process with the discharge sleeve check ball and O ring Repeat process for second check bore Replace check cap seals and tighten check bore caps to 50in lbs Install shaft seals into shaft bore grooves Thread shaft into push plate until engagement with the shaft shoulder is achieved Additionally apply a turn to ensure proper installation Insert sh...

Page 19: ... into slave head Carefully place and press the body assembly onto the tie bolts transfer tubes seals and slave head Install the remaining diaphragm set onto the tie bolts and body again noting formed main seal groove and transfer port seals O rings Install seal onto protruding pilot transfer tube Place the main seal O ring into the formed groove of the master head Place remaining main transfer tub...

Page 20: ... cycling is achieved Increase pressure to 60 psi Check for fluid leaks listen for air leaks check for irregularity Prepare the pump for drying 4 9 b Dry Pump Connect vacuum hose to discharge line Connect purge line to fluid inlet 60 psig Supply Pressure Cycle pump vacuum dry by rotating pump side to side for 30 seconds Turn off Air Supply and allow the pump to purge for 5 minutes 4 9 c Dry Suction...

Page 21: ...ion dead head Remove obstruction Refer to Section 0 for further information on Dead Head condition Shuttle valve spool may be centered Turn off air supply Disconnect supply tube at pump fitting to bleed internal pressure Reconnect and turn on air Remove shuttle cap and push the spool to end of travel Replace cap start pump Bubbles in Fluid Discharge Cause Solution Leaking fluid inlet fitting Tight...

Page 22: ...estriction Reduce distance height of suction head Increase diameter of suction supply line reduces restriction Fluid supply line pressure Adjust check muffler assembly see 0 Pilot valve not seating Check pilot valve function and seal Additional TFE thread tape on pilot valve threads Pilot valve transfer O rings leaking Check diaphragm hole alignment Replace O ring seals Check ball s not seating Re...

Page 23: ...l warranty related freight costs shall be borne by the customer Excessive wear to pump components caused by pumping abrasive solutions or chemicals as well as damage caused by ingesting foreign objects shall not be covered by this warranty This warranty shall not apply to any equipment which in the judgment of TREBOR shall have been repaired or altered outside TREBOR s factory in any way so as to ...

Page 24: ... 0303 Toll Free Number 800 669 1303 Fax Number 801 255 2312 Email treborinfo idexcorp com treborsales idexcorp com Address Trebor International 8100 South 1300 West West Jordan Utah 84088 U S A 7 2 TECHNICAL SUPPORT Email treborservice idexcorp com Phone Number 801 244 6156 7 3 REGIONAL REPRESENTATIVES Web http www treborintl com about_contact_us asp ...

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