Trebor Mega 960D Operation & Maintenance Manual Download Page 31

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MEGA 960D PUMP OPERATION / MAINTENANCE MANUAL

PAGE 31

8.2 MAGNETIC SHUTTLE ADDENDUM

Conversion Kits (Maxim 50D, Evolve 55D, Mega 960D & Mega 120D)

KUL0131

– Converts Standard Pumps to Magnetic Shuttle

KUDP-C-2

– Converts Pumps with Cycle Probe to Magnetic Shuttle

Rebuild Kit Item Number Changes

KR50D-00-B TO KR50D-00-C

KRE55D-00-A TO KRE55D-00-B

KR960D-00-C TO KR960D-00-D

KR120D-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

•

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.

Summary of Contents for Mega 960D

Page 1: ...7 23 20 M960D D Phone 800 669 1303 or 801 561 0303 Fax 801 255 2312 e mail treborservice idexcorp com Mega 960D 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 23 4 9 a Performance Test 23 4 9 b Dry...

Page 3: ... 4 4 Parts Illustration from both sides of all 8 tie bolts 2 Apply 60 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 The pump is mounted using four 1 4 bolts It is recommended that the pump be mounted no...

Page 4: ...NANCE 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 NOTE 1 It is recommended that a filter be placed on the discharge side of the pump ...

Page 5: ...tensive 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 5 5 bar Maximum fluid temperature 212 F 100 C ...

Page 6: ...r other rigid plumbing Available Options A PFA Weldable pipe 3 4 and 1 B Flare style tube adapter 3 4 and 1 C PFA tube stub out 3 4 D NPT adapter nut 3 4 and 1 E PILLAR Super 300 1 Not Shown Figure 2 1 2 2 FLUID FITTINGS SURGE SUPPRESSOR HOOK UP Surge Suppressor Assembled Height IN CM SS85 17 12 43 49 SS95 15 06 38 25 Figure 2 2 A B C D ...

Page 7: ...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 provided Figu...

Page 8: ... 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 head suction line restrictions discharge h...

Page 9: ...ure Capacity Chart NOTE Test information is based on specific conditions and limited sampling Use for general reference only MTD0371 0 10 20 30 40 50 60 70 80 90 0 5 10 15 20 25 Flow Capacity GPM Discharge Pressure PSIG 20 psi 30 psi 40 psi 50 psi 60 psi 70 psi 80 psi ...

Page 10: ...umps 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 foll...

Page 11: ...nths 24 Months Tie Bolt Torque 60 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: ...Ring PTFE 98002303 4 O Ring 98002740 4 Check Ball 98003047 2 Seal Quick Exhaust L0100 16 Tie Bolt Cap L0163 L0164 2 2 Check Cap Seal Fluid Port Seal L0192 1 Shaft Bushing 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 KT960 00 B Tool Kit which includes Part No Qty Description 9800123...

Page 14: ...PAGE 14 MEGA 960D PUMP OPERATION MAINTENANCE MANUAL 4 4 PARTS ILLUSTRATION ...

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: ...t bushing 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...

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: ...side 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 adapter detent and Shuttle Sleeve Do not lubricate Figure 4 4 Install the seal onto seal groove shoulder of the shuttle cap Thread shuttle cap onto detent adapter Tighten to 40 in lbs ...

Page 20: ...ach muffler pads onto muffler spool and insert into exhaust port Tighten to 40in lbs 4 8 e Body Assembly NOTE For easy installation check sleeves that do not install easily minimal effort can be placed in a freezer prior to assembly to assist insertion Body must be upside down with check port extending over a table edge so that parts remain assembled during insertion of sleeves See Figure 4 6 Inse...

Page 21: ... 6 NOTE The suction sleeves are 2 1 2 6 35 cm long The discharge sleeves are 2 846 7 2cm long Repeat insertion process with the discharge sleeve check ball O ring and wear ring Place seal and tighten check bore caps 60 in lbs Repeat process for second check bore ...

Page 22: ...into hole and tighten until flush with locking ring Thread one push plate onto shaft until push plate bottoms out on shaft shoulder 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 body Install push plate locking screw Tighten to 12 oz in Figure 4 8 Insert shaft...

Page 23: ...head ensuring alignment of shuttle transfer tube and its corresponding body passage hole Place remaining two diaphragms onto tie bolts body and shuttle transfer tube Note main seal groove alignment Place two O rings onto shuttle transfer tube Place the main seal O ring into the formed groove of the slave head Place a second main transfer tube and O ring into slave head Lift the slave head and body...

Page 24: ... or leaks Open discharge valve and expel the remaining DI water 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 Suction Valu...

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 60 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 60 in lbs Replace tran...

Page 27: ...MEGA 960D 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 801 561 0303 7 3 REGIONAL REPRESENTATIVES Web http www treborintl com distributors ...

Page 29: ...on sleeve L0193 into check bore of pump body 2 Press suction sleeve L0193 into check bore using sleeve insertion tool T000B0007 3 Insert check seat wear ring L0191 o ring 98002261 check ball 98002740 and discharge sleeve L0096 01 into check bore of pump body 4 Press discharge sleeve L0196 01 into check bore using sleeve insertion tool T000B0007 5 Insert check sleeve alignment tool T0229 into disch...

Page 30: ... alignment tool T0229 as shown 7 Install check sleeve plug L0227 into discharge sleeve L0196 01 using pin tool T0148 and drive extension T0182 as shown 8 Torque check sleeve plug L0227 to 35 in lbs 9 Install check port seal L0163 01 and check cap L0154 01 as shown 10 Torque check cap L0154 01 to 60 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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