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MEGA 120D PUMP OPERATION / MAINTENANCE MANUAL

PAGE 11

MEGA 120D Maintenance Schedule

In

stall

30 Days

3 Months

6 Months

9 Months

12 Months

15 Months

18 Months

21 Months

24

Months

Tie Bolt Torque (80 lb.-in)

I

I

I

I

I

C-Ring and Detent Legs

R

Pilot Button

R

Check Seat Wear Rings

R

Shaft Bushing

R

Shaft (High Suction Applications)

R

Shaft

R

Diaphragms and Main Seal

R

Quick Exhaust Seal

R

Check Balls and O-Rings

R

Check Balls and O-Rings

(High Suction Applications)

R

Exhaust Muffler Media

R

Distribution Pilots

R

I=Inspect, R=Replace

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Summary of Contents for Mega 120D

Page 1: ...7 23 20 M120D A Phone 800 669 1303 or 801 561 0303 Fax 801 255 2312 E mail treborservice idexcorp com Mega 120D PUMP Operation Maintenance Manual ...

Page 2: ...RTS 13 4 3 TOOLS 13 4 4 PARTS ILLUSTRATION 14 4 5 PARTS LIST 15 4 6 CLEAN UP 16 4 7 DISASSEMBLY 16 4 7 a Head Disassembly 16 4 7 b Body Disassembly 17 4 8 ASSEMBLY 17 4 8 a Pilot Valve Both Heads 17 4 8 b Shuttle Spool Assembly 18 4 8 c Shuttle Assembly Master Head 19 4 8 d Quick Exhaust Both Heads 20 4 8 e Body Assembly 20 4 8 f Final Assembly 23 4 9 TESTING 24 4 9 a Performance Test 24 4 9 b Dry...

Page 3: ... both sides of all 8 tie bolts 2 Apply 80 in lbs 9 0 N m 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 the tie bolt caps 1 3 UTILITIES HOOK UP The pump is mounted using four 1 4 bolts It is recommended that the pump be mounted not more than 15 f...

Page 4: ...ump 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 Maximum supply CDA N2 pressure 80 psig 0 55 MPa Maximum fluid temperature 212 F 100 C MEASUREMENTS ARE IN mm in ...

Page 5: ...tions A Flare style tube adapter 1 1 4 tube fitting made of high purity PFA PVDF flare nuts standard PFA flare nuts optional B Custom fittings Contact Trebor Representative 2 2 FLUID FITTINGS SURGE SUPPRESSOR HOOK UP Surge Suppressor Assembled Height mm in SS85P5A0 434 9 17 12 SS95P5A0 382 5 15 06 Figure 2 1 ...

Page 6: ... seal from port Install probe assembly into leak sensor port Probe is self sealing and does not require a seal Thread probe cap into port NOTE Do not over tighten damage to threads will occur 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 pr...

Page 7: ...MEGA 120D PUMP OPERATION MAINTENANCE MANUAL PAGE 7 Figure 2 3 ...

Page 8: ... When handling potentially dangerous fluids under pressure the pump and its 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 3 2 PERFORMANCE CHARTS Pumping capacity is a function of air supply pressure and volume suction...

Page 9: ...MEGA 120D PUMP OPERATION MAINTENANCE MANUAL PAGE 9 Figure 3 2 ...

Page 10: ... 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 followin...

Page 11: ...nths 24 Months Tie Bolt Torque 80 lb in I I I I I C Ring and Detent Legs R Pilot Button R Check Seat Wear Rings R Shaft Bushing R Shaft High Suction Applications R Shaft R Diaphragms and Main Seal R Quick Exhaust Seal R Check Balls and O Rings R Check Balls and O Rings High Suction Applications R Exhaust Muffler Media R Distribution Pilots R I Inspect R Replace ...

Page 12: ..._ ________________________________________ Date ________ Tech _____ Notes ________________________________________ ________________________________________ Date ________ Tech _____ Notes ________________________________________ ________________________________________ Date ________ Tech _____ Notes ________________________________________ ________________________________________ Date ________ Tech...

Page 13: ... O Ring 98004255 4 Check Ball BL002 2 Suction Seat BL007 2 Check Port Gasket BL009 2 Fluid Port Gaskets BL012 1 Shaft Bushing L0100 16 Tie Bolt Cap In critical applications a spare pump is recommended to minimize potential down time 4 3 TOOLS The following tool kit is recommended as standard service equipment KT120 00 A Tool Kit which includes Part No Qty Description 98001230 1 5 32 Allen Wrench 9...

Page 14: ...PAGE 14 MEGA 120D PUMP OPERATION MAINTENANCE MANUAL 4 4 PARTS ILLUSTRATION Figure 4 1 ...

Page 15: ... 22 AM040 2 Leak Port Cap PP 23 L0167 2 Leak Port Seal PTFE 24 98003047 2 Quick Exhaust Seal 1 Viton 25 1900B0016 2 Quick Exhaust Port UHMW 26 L0119 2 Muffler Assembly 1 PP 27 98003080 2 Plug Remote Exhaust PE 28 AK058 1 NM Sleeve Assembly Ceramic PTFE 29 L0105 1 Adapter Detent PP 30 L0131 1 Assembly Spool External High Load Ceramic PEEK Torlon 30A L0197 2 Leg Detent 1 Torlon 30B L0145 1 Ring Dete...

Page 16: ...diaphragms Remove the O rings from the shuttle transfer tube Remove the body assembly Remove the second set of diaphragms and main seal Remove the transfer tube and O rings from the heads and body Remove the remaining tie bolt caps and tie bolts NOTE All polypropylene and fluoroplastic parts when disassembled should be thoroughly washed and be free from chemical residue for handling purposes 4 7 a...

Page 17: ...hing from the slave head chamber side 4 8 ASSEMBLY Prior to beginning assembly inspect all parts to ensure they are clean and dry Wear clean protective gloves 4 8 a Pilot Valve Both Heads NOTE Do not use any tools to install the pilot button Use of tools may damage the button Remove existing pilot button and discard Replacement pilot button should be tightened enough that the underside of the head...

Page 18: ... align slot in detent legs item 2 with notch on shuttle spool see Fig 1 Apply pressure 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 th...

Page 19: ...stallation Thread detent adapter into shuttle bore until flush against head Tighten to 45 in lbs Insert shuttle spool assembly into adapter detent and Shuttle Sleeve Do not lubricate Figure 4 5 Install the seal onto seal groove shoulder of the shuttle cap Thread shuttle cap onto detent adapter Tighten to 40 in lbs ATTENTION Threads should be snug Do not over tighten ...

Page 20: ...g the check sleeve insertion tool until the suction seat is at the bottom of the check bore Install the o ring The o ring should rest inside the cup shape in the seat Install the check ball Ensure the o ring does not become dislodged Insert the suction sleeve Press firmly using the check sleeve insertion tool until the suction sleeve meets the suction seat Install the o ring The o ring should rest...

Page 21: ...TION MAINTENANCE MANUAL PAGE 21 Figure 4 7 NOTE The suction sleeves are shorter than the discharge sleeves Insert the gasket seal Thread on the check port plug and tighten to 120 in lbs Repeat process for second check bore ...

Page 22: ...ssure that the shaft bushing does not move Insert locking screw into hole and tighten until flush with locking ring Thread one push plate onto shaft until push plate bottoms out on shaft shoulder See Figure 4 9 Tighten push plate to 48 oz in and then rotate CW until locking screw hole is aligned with the next available hole in shaft The first push plate can be visually aligned separate from the bo...

Page 23: ...on for reference Insert tie bolts into master head press fit and lay head flat with tie bolts sticking up Insert main transfer tube and O ring into head Install shuttle transfer tube with two O rings Place main seal into the main seal groove in master head Install two diaphragms removing all air from between diaphragms onto the tie bolts and shuttle transfer tube Note main seal groove alignment Pl...

Page 24: ...ply at 0 psi open the air supply valve Increase the air pressure until the pump starts to cycle Record the start pressure Target 20psig Pump must prime once even cycling is achieved Increase pressure to 80 psi Check for fluid leaks listen for air leaks check for irregularity Close the discharge valve and deadhead for 2 minutes Pump must not experience jog erratic cycling or leaks Open discharge va...

Page 25: ...sembly Fluid discharge line blocked Downstream valve closed filter plugged or other obstruction Remove obstruction Bubbles in Fluid Discharge Cause Solution Leaking fluid inlet fitting Tighten or remove and wrap with TFE thread tape prior to tightening Replace adapter O ring Leaking main seal Tighten tie bolt nuts to 80 in lbs Replace main seals if damaged Pump inlet line pressure reached saturati...

Page 26: ...not seating Check for particles between seal and port Replace seal Pilot valve not following diaphragm correctly Pilot valve piston must slide freely full travel in pilot valve sleeve Replace damaged pilot valve assembly Check ball s not seating Check O rings for damage replace if necessary Make sure check balls move freely in sleeves Pilot transfer leak Tighten tie bolts to 80 in lbs Replace tran...

Page 27: ...MEGA 120D PUMP OPERATION MAINTENANCE MANUAL PAGE 27 6 WARRANTY AND EXCLUSIONS See the Trebor Standard Limited Warranty at https www treborintl com sites default files TreborStandardLimitedWarranty pdf ...

Page 28: ...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 801 244 0303 7 3 REGIONAL REPRESENTATIVES Web http www treborintl com distributors ...

Page 29: ...f pump body 2 Press check seat BL002 into check bore using sleeve insertion tool T0172 3 Insert o ring 98004258 check ball 98004255 and suction sleeve BL003 into check bore of pump body 4 Press suction sleeve BL003 into check bore of pump body using sleeve insertion tool T0172 5 Insert o ring 98004258 check ball 98004255 and discharge sleeve BL004 01 into check bore of pump body ...

Page 30: ...into discharge sleeve BL004 01 8 Align discharge sleeve BL004 01 using check sleeve alignment tool T0230 as shown 9 Install check sleeve plug BL029 into discharge sleeve BL004 01 using pin tool T0148 and drive extension T0182 as shown 10 Torque check sleeve plug BL029 to 35 in lbs 11 Install check port seal BL007 01 and check cap BL006 01 as shown 12 Torque check cap BL006 01 to 120 in lbs ...

Page 31: ... 00 A TO KR120D 00 B TO ORDER REPLACEMENT PUMPS WITH MAGNETIC SHUTTLE CONSULT FACTORY FOR NEW ITEM NUMBER Installation Instructions NOTE Ensure that the spool moves freely inside the sleeve prior to installation Thread detent adapter into shuttle bore until flush against head Tighten to 45 in lbs Insert shuttle spool assembly into shuttle adapter and shuttle sleeve Do not lubricate Figure 1 1 Inst...

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