Trebor Mega 120E Operation & Maintenance Manual Download Page 1

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SERIAL NUMBER (located on top of product):

PATENTS: U.S. 09642426, U.S. 06106246, U.S. 05971402, U.S. 05370507

11/72019 – M120E-A

Phone: 800-669-1303 or 801-561-0303

Fax: 801-255-2312

E-mail: [email protected]

Mega 120E PUMP

Operation / Maintenance Manual

Summary of Contents for Mega 120E

Page 1: ...on top of product PATENTS U S 09642426 U S 06106246 U S 05971402 U S 05370507 11 72019 M120E A Phone 800 669 1303 or 801 561 0303 Fax 801 255 2312 E mail treborservice idexcorp com Mega 120E PUMP Operation Maintenance Manual ...

Page 2: ...entive Maintenance Record 13 4 2 RECOMMENDED SPARE PARTS 14 4 3 TOOLS 14 4 4 PARTS ILLUSTRATION 15 4 5 PARTS LIST 16 4 6 CLEAN UP 16 4 7 DISASSEMBLY 16 4 7 a Quick Exhaust Muffler Disassembly 17 4 7 b Body Disassembly 17 4 8 ASSEMBLY 17 4 8 a Quick Exhaust Both Heads 17 4 8 b Body Assembly 18 4 8 c Final Assembly 21 4 9 TESTING 22 4 9 a Performance Test 22 4 9 b Dry Pump 22 4 9 c Dry Suction 22 5 ...

Page 3: ...m both sides of all 8 tie bolts6 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...

Page 4: ...PAGE 4 MEGA 120E PUMP OPERATION MAINTENANCE MANUAL 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 ...

Page 5: ... 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 ...

Page 6: ...e Options 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 SS85 434 9 17 12 SS95 382 5 15 06 Figure 2 1 ...

Page 7: ... leak probe fitting into port See Figure 2 3 for illustration Install probe assembly into fitting Probe is self sealing and does not require a seal Tighten nut 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 2 3 b Removal ...

Page 8: ...ANUAL 2 3 c Sensor Signal Specifications The sensor signal is normally closed In the event of a leak no light signal is returned to the sensor NOTE See your fiber optic sensor installation instructions for proper hook up and adjustment Figure 2 3 ...

Page 9: ...ON 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 sucti...

Page 10: ...PAGE 10 MEGA 120E PUMP OPERATION MAINTENANCE MANUAL Figure 3 2 ...

Page 11: ... 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 12: ... 24 Months Tie Bolt Torque 80 in lb I I I I I Check Seat Wear Rings R Shaft Bushing R Shaft High Suction Applications R Shaft R Diaphragms and Main Seal R Diaphragms and Main Seal HF R Diaphragms and Main Seal ACT 935 TMAH R Quick Exhaust Seal R Check Balls and O Rings R Check Balls and O Rings High Suction Applications R Exhaust Muffler Media R I Inspect R Replace ...

Page 13: ..._ ________________________________________ Date ________ Tech _____ Notes ________________________________________ ________________________________________ Date ________ Tech _____ Notes ________________________________________ ________________________________________ Date ________ Tech _____ Notes ________________________________________ ________________________________________ Date ________ Tech...

Page 14: ... Tie Bolt Cap BL002 2 Suction Seat BL007 2 Check Port Gasket BL009 2 Fluid Port Gasket 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 98002136 2 7 16 Nu...

Page 15: ...MEGA 120E PUMP OPERATION MAINTENANCE MANUAL PAGE 15 4 4 PARTS ILLUSTRATION Figure 4 1 ...

Page 16: ...A0028 01 8 Tie Bolt Washer SS316 26 98002341 8 Nut Flange SS 1 4 20 SS18 8 27 98001418 4 Insert SS18 8 28 BL017 1 Pump Base PP 29 98001093 4 Washer SS18 8 30 98001375 4 Screw SS18 8 31 98001108 4 Cap Blue LDPE 32 98003755 1 Screw Lock Ring PTFE 33 98003769 2 Screw Push Plate PTFE 34 AW073 2 End of Stroke Port Plug PTFE 4 6 CLEAN UP To help remove potentially dangerous chemicals the pump can be flu...

Page 17: ...s 4 7 b Body Disassembly Remove check bore plugs using 3 4 pin tool and remove seals Remove sleeves balls o rings and check seat Do not use excessive force Unthread push plate locking screw and push plate from the one side of the shaft Remove remaining shaft and push plate from body Unthread second locking screw and push plate from shaft Unthread shaft bushing locking screw from body Using 2 pin t...

Page 18: ...m 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 inside the cup shape in the seat Install the check ball Ensure the o ri...

Page 19: ...TION MAINTENANCE MANUAL PAGE 19 Figure 4 3 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 20: ...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 5 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 21: ...n 4 4 Parts Illustration for reference Insert tie bolts into head press fit and lay head flat with tie bolts sticking up Place main seal into the main seal groove in head Install two diaphragms removing all air from between diaphragms onto the tie bolts and shuttle transfer tube Note main seal groove alignment Place body assembly onto tie bolts and head Place remaining two diaphragms onto tie bolt...

Page 22: ...essure 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 20 psig Supply Pressure Target Record Suc...

Page 23: ...ation point due to high suction requirement Increase diameter of suction supply line reduces restriction Reduce output flow Ruptured perforated diaphragm Replace diaphragms Fluid Leaks Cause Solution Tie bolt torque not enough to effect seal Tighten all nuts to 80 in lbs Damaged main seal Replace Check for irregularities in diaphragm groove on pump body Check bore cap Tighten or remove and replace...

Page 24: ...PAGE 24 MEGA 120E PUMP OPERATION MAINTENANCE MANUAL 6 WARRANTY AND EXCLUSIONS 6 1 TREBOR STANDARD LIMITED WARRANTY https www treborintl com standard limited warranty ...

Page 25: ...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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