Idex TREBOR MAGNUM 620D PUMP Manual

SERIAL NUMBER (located on back of product):
PATENTS: U.S. 09642426, U.S. 06106246, U.S. 05971402, U.S. 05370507 3/10/20 –M620D-C
Phone: [phone] or 801-561-0303
Fax: [phone]
e-mail: [e-mail]
MAGNUM 620D PUMP
Operation / Maintenance
Manual

MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL CONTENTS
CONTENTS
1INSTALLATION............................................................................................................3
1.1 UNPACKING ......................................................................................................3
1.2 UTILITIES / HOOK-UP.......................................................................................3
2OPTIONS......................................................................................................................5
2.1 FLUID PORT CONNECTION OPTIONS............................................................5
2.2 FLUID FITTINGS / SURGE SUPPRESSOR HOOK-UP....................................5
3START-UP....................................................................................................................7
3.1 PERFORMANCE CHARTS................................................................................7
4MAINTENANCE..........................................................................................................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 ................................................................................................16
4.7.a Body Disassembly...............................................................................17
4.7.b Head Disassembly...............................................................................17
4.7.c Master Head Disassembly...................................................................17
4.7.d Pump Cleaning....................................................................................17
4.8 ASSEMBLY ......................................................................................................17
4.8.a Master Head Assembly .......................................................................18
4.8.b Pump Assembly...................................................................................19
4.8.c Final Assembly ....................................................................................21
4.9 TESTING ..........................................................................................................22
5TROUBLESHOOTING................................................................................................23
6WARRANTY ...............................................................................................................24
7CONTACT INFORMATION ........................................................................................25
7.1 GENERAL CONTACT INFORMATION............................................................25
7.2 TECHNICAL SUPPORT...................................................................................25
7.3 REGIONAL REPRESENTATIVES...................................................................25

MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL PAGE 3
1 INSTALLATION
1.1 UNPACKING
After unpacking, the pump should be checked for any damage that may have
occurred during shipment. Damage should be reported to the carrier
immediately.
The following items should be included within the shipping container:
Qty
Item
Description
1
620
Magnum 620 Pump
1
M620D
Operation/Maintenance Manual
1.2 UTILITIES / HOOK-UP
It is recommended that the pump be positioned within 15from level to maintain
self-priming ability and pumping efficiency. 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. [8mm] supply tube minimum).
Air Supply: 28-80 psig (1.7 –5.5 bar) clean dry air or nitrogen (see
Performance Charts, Section 3.1).
Fluid Ports: 1” NPSM – additional adaptor port options available.
Inlet/Outlet adaptor fittings and Surge Suppressor require
torqueing during pump installation. See Section 2 for hook-up
diagram and torque values.

PAGE 4 MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL
Figure 1-1: Dimensional Views
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.
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 Temperature

MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL PAGE 5
2 OPTIONS
2.1 FLUID PORT CONNECTION OPTIONS
NOTE 1: Use O-ring to seal stainless steel or other rigid plumbing.
Available Options
A) Flare style tube adapter….1/2” and 3/4"
B) PFA tube stub out………...3/4"
C) Pillar Super 300…………..3/4” OR 1”
D) PFA Weldable pipe……….3/4"
Figure 2-1
2.2 FLUID FITTINGS / SURGE SUPPRESSOR HOOK-UP
Surge Suppressor
Assembled Height: IN (CM)
MODEL SS40
12.63 (32.08)
MODEL SS85
14.97 (38.02)
A)
B)
C)
D)

PAGE 6 MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL
Figure 2-2
NOTE: See Surge Suppressor Operation Manual for detailed installation
instructions.

MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL PAGE 7
3 START-UP
•Pump air supply pressure must be regulated. (See Figure 3-2: Pressure vs.
Fluid Temperature Chart.)
•Open the fluid suction (IN) line valve, if necessary.
•Open the fluid discharge (OUT) line valve, if necessary.
•Start slowly with air regulator at low (> 25 psi) pressure setting. Increase
pressure to attain desired flow, up to the maximum rating (See Section 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, suction head,
suction line restrictions, discharge head, discharge line restriction, and fluid
specific gravity and viscosity.
NOTE: Specification to be used to size regulators and control valves.

PAGE 8 MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL
Figure 3-1: Flow Performance
NOTE: Test information is based on specific conditions and limited sampling. Use
for general reference only.

MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL PAGE 9
Figure 3-2: Pressure vs. Fluid Temperature Chart
Recommended Maximum Pump Operating Levels
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 10 MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL
4 MAINTENANCE
Trebor pump maintenance can be divided into two categories: air system
maintenance and fluid system maintenance. The purpose of air system
maintenance is to prevent air system failures such as stalling or erratic cycling.
The purpose of fluid system maintenance is to maintain suction and lift
capabilities.
Pump Rebuild Service
Trebor International provides a factory rebuild service for customers using Trebor
products. Trebor will rebuild any standard pump (exclusive of options). Please
contact Trebor International Sales Department for current rebuild pricing. The
fixed rebuild price includes a factory rebuild and parts equivalent to the standard
rebuild kit. Each factory rebuild comes with a new one-year warranty. Repairs
requiring more extensive part replacements will be quoted prior to proceeding
with the pump rebuild. If the pump has exceeded its useful life and cannot be
rebuilt, the customer may elect 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. 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 following maintenance schedule is recommended to optimize pump
performance and minimize failures. Certain operating conditions that require
more frequent maintenance intervals have been noted. In positive pressure inlet
conditions where suction or lift is not required, fluid system maintenance may be
extended.
Adhering to the recommended preventative maintenance schedule along with
periodic inspection of the pump will ensure continued efficient operation and
overall reliable pump performance.
It is recommended that the Preventive Maintenance Record (Section 4.1.a) be
copied, maintained and kept with this unit for future reference.

MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL PAGE 11
MAGNUM 620D Maintenance Schedule
Install
30 Days
3 Months
6 Months
9 Months
12 Months
15 Months
18 Months
21 Months
24 Months
Smart Pilot Assemblies
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 12 MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL
4.1.a Preventive Maintenance Record
Company Name:
_____________________________________________________
Company Address:
_____________________________________________________
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Product:
_________________
Serial Number:
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MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL PAGE 13
4.2 RECOMMENDED SPARE PARTS
KR620D-00-A Spares Rebuild Kit, which includes:
Part No
Qty
Description
KM620D-00-A
1
Maintenance Kit
Includes:
(2)
(2)
(1)
(2)
(8)
98002987
L0197
L0145
AW037
C0136
Pilot Button
Detent Legs
Detent Ring
Muffler Spool
Muffler Pad
KD620D-00-A
1
Diaphragm Kit
Includes:
(2)
AW105
Diaphragm
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 Tool
T0129
1
Strap Wrench
T0146
1
3/4” Pin Tool
T0154
1
Check Sleeve Insertion Tool
T0155
1
Shaft Bullet
T0157
1
Rebuild Fixture
T0144
1
Cleaning Tool

PAGE 14 MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL
4.4 PARTS ILLUSTRATION

MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL PAGE 15
4.5 PARTS LIST
ILL
NO
PART NO
QTY
DESCRIPTION
PM
YEAR #
MATERIAL
1
AW100
1
Detent Cap
PP
2
AW022
1
Detent Cap Seal
PTFE
3
AM068
1
Shuttle Spool Assembly
Ceramic, PEEK,
Torlon
4
AW023
1
Shuttle Locking Ring
PTFE
5
AK058
1
Shuttle Sleeve Assembly
Ceramic, PTFE
6
AW098
1
Master Head
PP
W0123
1
Smart Pilot Assembly (INCLUDES 7-11)
1
PEEK/PTFE
7
W0099
2
Pilot Sleeve Seal
PTFE
8
98002987
2
Pilot Button
PTFE
9
W0099
2
Pilot Sleeve
PEEK
10
98002302
2
O-Ring
FKM
11
W0122-01
2
Wear Resist Pilot Piston
PEEK
12
W0116
2
Pilot Cap Seal
PTFE
13
L0208
2
Pilot Cap
PP
15
C0136
8
Check Muffler Pad (Media)
1
PP
16
AW037
2
Check Muffler Spool
PP
17
AW105
2
Diaphragm
2
PTFE
18
98003722
2
Locking Screw, Push Plate
PTFE
19
AW071
2
Push Plate
PTFE
20
AW072
1
Shaft
2
PFA
21
98003322
2
Shaft seal
2
PTFE
22
98003395
4
Transfer Tube Fitting
PP
23
98001072
2
3/8” Tube
PFA
24
AW001
1
Body
PTFE
25
98002334
4
O-ring, PTFE Check Valve
2
PTFE
26
98001415
4
Check Ball
2
PTFE
27
AM060
2
Suction Sleeve
PTFE
28
AM061
2
Discharge Sleeve
PTFE
29
AM083
2
Check Cap Seal
2
PTFE
30
AW003
2
Check Bore Cap
PTFE
31
AW014
1
Damper Port Cap
PTFE
32
AW017
3
Damper and Adapter Port Seal
PTFE
33
AW099
1
Slave Head
PP
34
AW057
1
Base, Quick Release
PP
35
98003207
4
Base Mounting Screw
PP
36
98003071
1
Lever Mounting Screw
PP
37
AM023
1
Base Locking Lever
PP
38
C0102
1
Base
PP
4.6 CLEAN-UP
To help remove potentially dangerous chemicals prior to service or shipment, the
pump should be flushed with DI water or disassembled and thoroughly cleaned.
Allow DI water to flush through the inlet and out the outlet to prevent pressure
build up.
CAUTION: When handling pump, wear appropriate personal protection
gear, including safety glasses.

PAGE 16 MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL
4.7 DISASSEMBLY
During the life of the pump it will be necessary to perform certain preventive
maintenance procedures to 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. Reference the exploded view drawing
and parts list for assistance in identifying components.
•Immerse or flush the pump assembly using DI water and a neutralizing agent.
•Install mounting fittings in pump adapter ports and lock body into bench
mounting fixture. NOTE: Securely attach mounting fixture to work surface
using hardware provided.
Figure 4-1
•Remove transfer tubes and fittings from pump head.
Figure 4-2
•Using a strap wrench, turn heads counter-clockwise to remove.
•Remove head and check diaphragms for cracks or cuts.

MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL PAGE 17
•To remove diaphragms, slit diaphragm 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.)
•Unscrew push plate from the shaft in a counter-clockwise direction. Pull
other push plate and shaft from pump body.
CAUTION: Following disassembly, parts should be thoroughly washed to
be free from chemical residue for handling purposes.
4.7.a Body Disassembly
•Remove (2 each) check plugs and seal on top of pump body using 3/4” pin
tool.
•Remove discharge sleeve using sleeve removal tool.
•Remove PTFE ball and O-ring.
•Remove suction sleeve using sleeve removal tool.
•Remove second set of O-rings and balls.
•Remove shaft seals from pump shaft seal groove in the center of the shaft
bore using the tip of a razor knife. Take care not to damage the shaft bore.
NOTE: Do not reuse seals.
•Remove damper plug and seal using 3/4” pin tool.
4.7.b Head Disassembly
•Unscrew and remove pilot seat using 3/4” pin tool. Remove pilot.
4.7.c Master Head Disassembly
•Unscrew and remove muffler assembly from head using the 3/4” pin tool.
•Unscrew and remove the shuttle cap and seal.
•Remove spool assembly from shuttle bore.
•Remove detent legs and detent ring from spool.
•Do not remove the shuttle sleeve from the shuttle bore.
•Remove muffler assembly.
4.7.d Pump Cleaning
•Gently spray clean with DI water, or rinse by dunking all components in DI
water, to remove any trace materials remaining after disassembly.
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.

PAGE 18 MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL
4.8.a Master Head Assembly
Shuttle spool assembly instructions:
•Hold shuttle spool (item 1) upright and align slot 1 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 the
detent ring groove. See Fig. 3. The completed assembly should look like
Fig. 4 (see Figure 4-3).
Figure 4-3
•Insert spool assembly into shuttle sleeve (do not lubricate spool or sleeve).
•Install seal onto seal groove shoulder of shuttle cap.
•Thread shuttle cap into head.

MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL PAGE 19
Figure 4-4: Shuttle Assembly
ATTENTION: Threads should be snug. Do not over tighten.
•Thread muffler assembly into head using 3/4” pin tool.
4.8.b Pump Assembly
NOTE: Check sleeves that fit too tightly for easy installation should 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 4-5.)

PAGE 20 MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL
Figure 4-5
•Insert suction sleeve, check ball and O-ring carefully into check bore.
NOTE: The Suction Sleeves have a shoulder diameter larger than their body
diameter. Additionally the Suction Sleeves when compared to the Discharge
Sleeves have a thicker top region which acts as a robust 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 seals and tighten check bore caps to 45in-lbs.
•Install seal and damper plug using 3/4” pin tool. Torque to 45in-lbs.
•Install two shaft seals in shaft bore groove with slits 180apart.
•Thread shaft into push plate until engagement with the shaft shoulder is
achieved. Finally, apply a ¼” turn to ensure proper installation.
•Insert shaft through shaft bore using shaft bullet as shown (This prevents
damage to the TFE shaft seals and prevents dislodgement of shaft seals).