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MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL

PAGE 27

4.8 ASSEMBLY

Prior to beginning assembly, inspect all parts to ensure they are clean and dry.

Wear clean protective gloves. Precautions should be exercised to prevent

contaminating any of the air chamber surfaces with chemicals during handling.

•

Install o-rings (98002334), balls (98001415), and suction valve sleeve

(AM060) into each bore using the check valve insertion tool (T0154).

•

Install o-rings (98002334), balls (98001415), and discharge valve sleeve

(AM061) into each bore using the check valve insertion tool (T0154).

Figure 4-18

•

Using the ¾” pin tool (T0146), install new check bore seals (AM083) and

check bore caps (AW003). Torque to 60 in-lbs.

•

Using the ¾” pin tool (T0146), install new damper port seal (AW017) and

damper port cap (AW014). Torque to 45 in-lbs.

Figure 4-19

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Summary of Contents for MAGNUM 620D

Page 1: ... back of product PATENTS U S 09642426 U S 06106246 U S 05971402 U S 05370507 4 21 2022 M620D E Phone 800 669 1303 or 801 561 0303 Fax 801 255 2312 e mail treborservice idexcorp com MAGNUM 620D PUMP Operation Maintenance Manual ...

Page 2: ...tallation 8 2 5 OPTIONAL REMOTE EXHAUST 9 2 5 a Installation 9 3 START UP 10 3 1 PERFORMANCE CHARTS 10 4 MAINTENANCE 13 4 1 PREVENTIVE MAINTENANCE SCHEDULE 13 4 1 a Preventive Maintenance Record 15 4 2 RECOMMENDED SPARE PARTS 16 4 3 TOOLS 16 4 4 PARTS ILLUSTRATION 17 4 5 PARTS LIST 18 4 6 CLEAN UP 18 4 7 DISASSEMBLY 19 4 8 ASSEMBLY 27 4 9 TESTING 36 5 TROUBLESHOOTING 37 6 WARRANTY 38 7 CONTACT INF...

Page 3: ...cy Allow sufficient room for tubing connectors The pump mounts on a quick change base for easy installation The pump has an exhaust location on the backsides of the master and slave heads The exhaust location requires 1 2 12mm minimum clearance behind the master head Care should be taken to prevent flooding the exhaust port when the pump is located in a wet bench plenum Air Inlet 1 4 FNPT 3 8 Dia ...

Page 4: ...ge the pump NOTE 1 It is recommended that a filter be placed on the discharge side of the pump 2 Although extensive efforts are made to deliver pumps to our customers completely dry new pumps may contain residual moisture from their final DI water test Recommended Maximum Operating Levels Temperature Range Supply Pressure Max 60 C 80 PSI 5 5 bar 60 C 100 C 60 PSI 4 1 bar 100 C Maximum Fluid Temper...

Page 5: ...AL PAGE 5 2 OPTIONS 2 1 FLUID PORT CONNECTION OPTIONS Available Options A Flare style tube adapter 1 2 3 4 1 B PFA tube stub out 3 4 C Pillar Super 300 3 4 1 D PFA weldable pipe 3 4 E NPT adapter nut 3 4 Figure 2 1 Fluid Port Connection Options ...

Page 6: ... FLUID FITTINGS SURGE SUPPRESSOR HOOK UP Surge Suppressor Assembled Height IN CM MODEL SS40 12 63 32 08 MODEL SS85 14 97 38 02 Figure 2 2 Fitting Surge Suppressor Installation NOTE See Surge Suppressor Operation Manual for detailed installation instructions ...

Page 7: ...bly DP L 23 into the leak port of each head Thread the leak probe onto the probe fitting L0183 Torque the nut of the leak probe assembly hand tight Connect fiber optic cable to sensor NOTE Minimize bends in fiber optic cable to 2 radius minimum to help ensure optimum signal strength Fiber optic cable can be cut to desired length using the cable cutter provided Figure 2 3 Leak Probe Installation ...

Page 8: ...0142 of the cycle probe assembly DP C 2 Torque to 40 IN LBS Thread the cycle probe into the cycle probe cap L0142 Torque the cycle probe assembly hand tight Connect fiber optic cable to sensor NOTE Minimize bends in fiber optic cable to 2 radius minimum to help ensure optimum signal strength Fiber optic cable can be cut to desired length using the cable cutter provided Figure 2 4 Cycle Probe Insta...

Page 9: ...spools L0194 and muffler pads C0136 from each head Using the 3 4 pin tool T0146 install the remote exhaust plugs L0209 into each head Torque the remote exhaust plugs L0209 to 40 IN LBS Remove remote exhaust plug 98002243 from each head Install remote exhaust L0187 01 into the remote exhaust port of each head Figure 2 5 Remote Exhaust Installation ...

Page 10: ...ection 3 1 Refer to Troubleshooting Section 5 if pump fails to start ATTENTION Prolonged periods 5 minutes of dry running can damage critical internal pump parts CAUTION When handling potentially dangerous fluids under pressure the pump and its fittings should be placed in an enclosure away from operators 3 1 PERFORMANCE CHARTS Pumping capacity is a function of air supply pressure and volume sucti...

Page 11: ...MAGNUM 620D PUMP OPERATION MAINTENANCE MANUAL PAGE 11 Figure 3 1 Flow Performance Curves NOTE Test information is based on specific conditions and limited sampling Use for general reference only ...

Page 12: ... Figure 3 2 Max Operating Pressure vs Fluid Temperature NOTE 1 This graph is not representative of all operating conditions customer s specific application results may vary 2 Be sure that fittings and tubing used are capable of these operating conditions ...

Page 13: ...lect to purchase a new Trebor pump If the customer chooses not to rebuild or replace the pump an evaluation charge will be required All returned 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 Eac...

Page 14: ...le Install 30 Days 3 Months 6 Months 9 Months 12 Months 15 Months 18 Months 21 Months 24 Months Pilot Button R C Ring and Detent Legs R Muffler Media R Shaft Seal and Shaft R Check Balls and O Rings R Diaphragms R Check Plug Seal R Suction and Discharge Check Cage I I Inspect R Replace ...

Page 15: ...__ ________________________________________ Date ________ Tech _____ Notes ________________________________________ ________________________________________ Date ________ Tech _____ Notes ________________________________________ ________________________________________ Date ________ Tech _____ Notes ________________________________________ ________________________________________ Date ________ Tec...

Page 16: ...m 98001415 4 Check Ball 98002334 4 O ring PTFE 98003322 2 Shaft Seal AW072 1 Shaft AM083 2 Check Cap Seal AW017 1 Damper Port Seal 4 3 TOOLS The following tool kit is recommended as standard service equipment KT620 00 A Tool Kit which includes Part No Qty Description 98003108 1 Torque Wrench 30 150 ft lb 1 2 Drive Handle 98003150 1 Tool Case 98003305 1 Drive Handle T000B0014 1 Check Sleeve Removal...

Page 17: ...MAGNUM 620D PUMP OPERATION MAINTENANCE MANUAL PAGE 17 4 4 PARTS ILLUSTRATION Figure 4 1 Exploded View ...

Page 18: ... 2 Pilot Valve Seal PTFE 15 AW098 1 Master Head PP 16 AW105 2 Diaphragm 2 PTFE 17 98003722 2 Screw PTFE 18 AW071 2 Push Plate PTFE 19 AW072 1 Shaft 2 PFA 20 98003322 2 Shaft Seal 2 PTFE 21 AW001 1 Body PTFE 22 98003395 4 Transfer Tube Fitting PP 23 98001072 2 3 8 Tube PFA 24 AM060 2 Suction Sleeve PTFE 25 98002334 4 O ring 2 PTFE 26 98001415 4 Check Ball 2 PTFE 27 AM061 2 Discharge Sleeve PTFE 28 ...

Page 19: ...ensure its continued high performance This section and the next 4 8 Assembly are provided for the user s convenience in disassembly and re assembly procedures Immerse or flush the pump assembly using DI water and a neutralizing agent Remove lever lock base from bottom of pump Figure 4 2 Remove screws 98003207 and quick change base AW057 from the bottom of the pump Figure 4 3 ...

Page 20: ...0D PUMP OPERATION MAINTENANCE MANUAL Remove tube fittings 98003395 and tubing from the back of the pump Figure 4 4 Using 1 pin tool T0147 remove the muffler spools L0194 and muffler pads C0136 from each head Figure 4 5 ...

Page 21: ...xhaust ports 1900B0016 and quick exhaust seals 98003047 from each head Figure 4 6 Using the pin tool T0146 remove the pilot caps L0208 and pilot cap seals W0116 from each head Figure 4 7 Using the pin tool T0146 remove the pilot valves W0123 and pilot valve seals W0117 from each head Figure 4 8 ...

Page 22: ...D PUMP OPERATION MAINTENANCE MANUAL Using the pin tool T0146 remove the shuttle cap L0104 the shuttle cap seal L0113 and shuttle L0131 Figure 4 9 Using the pin tool T0146 remove the shuttle cap adapter L0105 Figure 4 10 ...

Page 23: ...ody into bench mounting fixture T0136 NOTE Securely attach mounting fixture T0136 to work surface using hardware provided Figure 4 11 Wrap the strap wrench around the head AW099 as shown and with the aid of a drive ratchet wrench turn the head counter clockwise to remove Repeat process for other head AW098 Figure 4 12 ...

Page 24: ...agm with a sharp knife and pull the diaphragms from the grooves Do not pry on diaphragm seal groove as this will damage the sealing surface Figure 4 13 Remove locking screw 98003722 from push plate AW0741 using a slotted screwdriver Using the pin tool T0146 remove push plate AW071 from shaft assembly Then remove the shaft assembly from the pump Figure 4 14 ...

Page 25: ...ew 98003722 from push plate AW0741 using a slotted screwdriver Using the pin tool T0146 remove push plate AW071 from shaft AW072 Figure 4 15 Remove shaft seals 98003322 from the shaft bore Using the pin tool T0146 remove the damper port cap AW014 and seal AW017 Figure 4 16 ...

Page 26: ...e check bore caps AW003 and seals AW003 Using the check sleeve removal tool T000B0014 remove the check valve components from each check bore Figure 4 17 Gently spray clean with DI water or rinse by dunking all components in DI water to remove any trace materials remaining after disassembly ...

Page 27: ... Install o rings 98002334 balls 98001415 and suction valve sleeve AM060 into each bore using the check valve insertion tool T0154 Install o rings 98002334 balls 98001415 and discharge valve sleeve AM061 into each bore using the check valve insertion tool T0154 Figure 4 18 Using the pin tool T0146 install new check bore seals AM083 and check bore caps AW003 Torque to 60 in lbs Using the pin tool T0...

Page 28: ...t Figure 4 20 Thread push plate AW071 onto shaft AW072 until the plate contacts the shaft shoulder Continue tightening until the locking screw hole of the plate aligns with the next available hole in the shaft Install the thread locking screw with a slotted screwdriver Install the shaft bullet T0155 onto opposite end of shaft Figure 4 21 ...

Page 29: ...let from end of shaft Figure 4 22 Thread push plate AW071 onto shaft AW072 until the plate contacts the shaft shoulder Continue tightening until the locking screw hole of the plate aligns with the next available hole in the shaft Install the thread locking screw with a slotted screwdriver Figure 4 23 ...

Page 30: ...hown Thread hand tight Install diaphragm AW105 and master head AW098 onto pump as shown Thread hand tight Figure 4 24 Install mounting fittings T0156 into pump fluid ports and lock body into bench mounting fixture T0136 NOTE Securely attach mounting fixture T0136 to work surface using hardware provided Figure 4 25 ...

Page 31: ...he head AW099 as shown and with the aid of a drive ratchet wrench turn the head clockwise to tighten until the exhaust ports face the bottom of the pump Repeat process for other head AW098 Figure 4 26 Using the pin tool T0146 install shuttle cap adapter L0105 Torque to 45 in lbs Figure 4 27 ...

Page 32: ...ressure upward onto base of detent legs with thumb and index finger as shown in Fig 2 Tilt the detent ring item 3 over one of the legs and align the groove on the inside of the detent ring with the end of the detent leg Tilt the other side of the ring down expanding it slightly so that the other detent leg snaps into the detent ring groove See Fig 3 The completed assembly should look like Fig 4 Fi...

Page 33: ...sing the pin tool T0146 torque shuttle cap L0104 to 40 IN LBS Figure 4 29 Using the pin tool T0146 install the pilot valves W0123 and pilot valve seals W0117 into each head Torque the pilot valves W0123 to 25 in lbs Figure 4 30 Using the pin tool T0146 install the pilot cap seals W0116 and pilot caps L0208 into each head Torque the pilot caps L0208 to 45 in lbs Figure 4 31 ...

Page 34: ...k exhaust seals 98003047 and quick exhaust ports 1900B0016 into each head Torque the quick exhaust ports 1900B0016 to 15 in lbs Figure 4 32 Using the 1 pin tool T0147 install the muffler pads C0136 and muffler spool L0194 into each head Torque the muffler spools L0194 to 40 in lbs Figure 4 33 ...

Page 35: ... 1 2 turns until tube ports are facing each other across the pump body Install transfer tubes 98001072 into the tube fittings 98003395 as shown Figure 4 34 Install quick change base AW057 with notched tab facing the front of the pump and screws 98003207 onto the bottom of the pump body with a slotted screwdriver Attach quick change base AW057 to lever lock base Figure 4 35 ...

Page 36: ...e achieved Increase pressure to 60 psi and allow pump to run for 5 minutes Check for fluid leaks listen for air leaks and check for irregularity Prepare the pump for drying 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 m...

Page 37: ...to high suction requirement Increase diameter of suction supply line reduces restriction Reduce output flow Ruptured perforated diaphragm Replace diaphragms Check bore caps leaking Tighten check bore caps or replace seals Fluid Leaks Cause Solution Head torque not enough to affect seal Remove heads and allow them to sit for 1 hour Reassemble with new diaphragms Leaking main seal Replace diaphragms...

Page 38: ... 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 a...

Page 39: ... 561 0303 Toll Free Number 800 669 1303 Fax Number 801 565 1510 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 801 561 0303 7 3 REGIONAL REPRESENTATIVES Web http www treborintl com distributors ...

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