Trebor Mega 120D Manual

7/23/20 –M120D-A
Phone: [phone] or 801-561-0303
Fax: [phone]
E-mail: [e-mail]
Mega 120D PUMP
Operation / Maintenance Manual

MEGA 120D PUMP OPERATION / MAINTENANCE MANUAL CONTENTS
CONTENTS
1INSTALLATION............................................................................................................3
1.1 UNPACKING ......................................................................................................3
1.2 TIE BOLT TORQUE ...........................................................................................3
1.3 UTILITIES / HOOK-UP.......................................................................................3
2OPTIONS......................................................................................................................5
2.1 FLUID PORT CONNECTION OPTIONS............................................................5
2.2 FLUID FITTINGS / SURGE SUPPRESSOR HOOK-UP....................................5
2.3 OPTIONAL LEAK SENSING..............................................................................6
2.3.a Installation..............................................................................................6
3START-UP....................................................................................................................8
3.1 HIGH TEMPERATURE OPERATION................................................................8
3.2 PERFORMANCE CHARTS................................................................................8
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........................................................................................................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 Pump.............................................................................................24
4.9.c Dry Suction..........................................................................................24
5TROUBLESHOOTING................................................................................................25
6WARRANTY AND EXCLUSIONS..............................................................................27
7CONTACT INFORMATION........................................................................................28
7.1 GENERAL CONTACT INFORMATION............................................................28
7.2 TECHNICAL SUPPORT...................................................................................28
7.3 REGIONAL REPRESENTATIVES...................................................................28
8ADDENDA ..................................................................................................................29
8.1 DISCHARGE SLEEVE ADDENDUM ...............................................................29
8.2 MAGNETIC SHUTTLE ADDENDUM ...............................................................31

MEGA 120D 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
120D
Mega 120D Pump
1
M120D
Operation/Maintenance Manual
1.2 TIE BOLT TORQUE
The tie bolts on the pump are tightened before leaving the factory. However, relaxation
may occur due to handling, material creep, or other unforeseen events. Trebor
recommends that all eight tie bolts be re-tightened upon pump install. The following
procedure should be used:
1. Remove black tie bolt caps (Item 17 in Figure 4-1) from 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from level to maintain self-priming ability and pumping
efficiency.
Air Inlet: 1/2” FNPT (3/8” Dia. [8mm] supply tube minimum).
Air Supply: 25-80 psig (0.17-0.55 MPa) clean dry air or nitrogen. (For Air
Consumption, See Section 3.1 Performance Charts)
Fluid Ports: Inlet/Outlet Fluid Fittings and Surge Suppressor require tightening to
specified torque values during pump installation. See Section 2 for
installation diagram and torque values.
Remote
Exhaust: 1/4” FNPT (3/8” Dia. minimum tube up to 6’ length, 1/2” Dia. Minimum
tube greater than 6’ length).

PAGE 4 MEGA 120D 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.
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]

MEGA 120D PUMP OPERATION / MAINTENANCE MANUAL PAGE 5
2 OPTIONS
2.1 FLUID PORT CONNECTION OPTIONS
Available 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)
SS85P5A0
434.9 (17.12)
SS95P5A0
382.5 (15.06)
Figure 2-1

PAGE 6 MEGA 120D PUMP OPERATION / MAINTENANCE MANUAL
Figure 2-2
NOTE: See Surge Suppressor Operation Manual for detailed installation instructions.
2.3 OPTIONAL LEAK SENSING
2.3.a Installation
•Remove plug and 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 provided.

MEGA 120D PUMP OPERATION / MAINTENANCE MANUAL PAGE 7
Figure 2-3

PAGE 8 MEGA 120D PUMP OPERATION / MAINTENANCE MANUAL
3 START-UP
•Pump air supply pressure should be regulated.
•Open the fluid suction (IN) line valve, if necessary.
•Open the fluid discharge (OUT) line valve, if necessary.
•Start with air regulator at low pressure setting (<15 psig). Increase or decrease
setting to attain desired flow, up to 80 psig (0.55 MPa).
•Refer to Troubleshooting, Section 5, if pump fails to start.
ATTENTION: Prolonged periods of dry running (> 5 minutes) will damage critical internal
pump parts.
CAUTION: 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 head, suction
line restrictions, discharge head, discharge line restriction, and fluid properties. The
following data was taken using water at atmospheric temperature and pressure with
limited sample sizes. The data is intended to aid in system design and should be used
for general reference only.
Figure 3-1

MEGA 120D PUMP OPERATION / MAINTENANCE MANUAL PAGE 9
Figure 3-2

PAGE 10 MEGA 120D 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 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, a $150.00
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. Tie bolt torque should be checked within 30 days of start-up and
at periodic intervals thereafter. If the pump is subjected to thermal cycle operation, the
tie bolt torque should be checked after the first 3 thermal cycles and periodically
thereafter. 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. However, tie bolt retorque is
still recommended.
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.

MEGA 120D PUMP OPERATION / MAINTENANCE MANUAL PAGE 11
MEGA 120D Maintenance Schedule
Install
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

PAGE 12 MEGA 120D PUMP OPERATION / MAINTENANCE MANUAL
4.1.a Preventive Maintenance Record
Company Name:
_____________________________________________________
Company Address:
_____________________________________________________
_____________________________________________________
Product:
_________________
Serial Number:
________________
Date:
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MEGA 120D PUMP OPERATION / MAINTENANCE MANUAL PAGE 13
4.2 RECOMMENDED SPARE PARTS
KR120D-00-A Spares Rebuild Kit, which includes:
Part No
Qty
Description
KD120-00-A
1
Diaphragm Kit*
Includes:
(2)
(2)
1900B0023
98001585
Diaphragm Set
FKM O-Ring
KM120D-00-A
1
Maintenance Kit
Includes:
(2)
(2)
(2)
(2)
(2)
(1)
1900B0016
98002987
98003047
L0119
L0197
L0145
Quick Exhaust Port
Pilot Button
Quick Exhaust Seal
Muffler Assembly
Detent Leg
Detent Ring
98002240
2
FKM O-Ring
98004258
4
O-Ring, PTFE
98002303
4
FKM 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
98002136
2
7/16” Nut Driver
98002859
1
7/16” Socket
98003150
1
Tool Case
98003305
1
Drive Handle
T0172
1
Check Sleeve Insertion Tool
T0173
1
Check Sleeve Removal Tool
T0146
1
¾” Pin Tool
T0147
1
1” Pin Tool
T0148
1
½” Pin Tool
T0159
1
2” Pin Tool
T0144
1
Cleaning Tool
T000A0021
1
Shaft Bullet

PAGE 14 MEGA 120D PUMP OPERATION / MAINTENANCE MANUAL
4.4 PARTS ILLUSTRATION
Figure 4-1

MEGA 120D PUMP OPERATION / MAINTENANCE MANUAL PAGE 15
4.5 PARTS LIST
ILL
NO
PART NO
QTY
DESCRIPTION
PM
YEAR #
MATERIAL
1
BL006
2
Check Bore Plug
PTFE
2
BL007
2
Gasket Seal, Check Port
1
PTFE
3
BL004
2
Discharge Sleeve
PTFE
4
98004255
4
Check Ball
1
PTFE
5
98004258
4
O-Ring
1
PTFE
6
BL003
2
Suction Sleeve
PTFE
7
BL002
2
Suction Seat
PTFE
8
BL001
1
Body
PTFE
9
BL012
1
Shaft Bushing
1
PTFE
10
L0195
1
Locking Ring
PTFE
11
BL011
1
Main Shaft
2
PFA
12
1900B0070
2
Push Plate
PTFE
13
1900B0023
2
Diaphragm Set
1
PFA
14
98001585
2
Main Seal
1
Viton
15
L0141-01
1
Master Head
PP
16
BL014
8
Tie Bolt Assembly
SS302, PFA
17
L0100
16
Tie Bolt Cap
1
LDPE
18
L0208
2
Cap, Pilot
PP
19
W0116
2
Seal, Pilot Cap
PTFE
20
W0123
2
Assembly, Pilot Valve, Wear Resistant
Peek, PTFE,
PPS, Viton
21
W0117
2
Seal, Pilot Sleeve
PTFE
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, Detent, High Load
1
PEEK
31
L0113
1
Seal, Detent Cap
PTFE
32
L0104
1
Cap, Detent External
PP
33
L0139-01
1
Slave Head
PP
34
L0140
8
Bushing
NPRN,EPD
M
35
1900A0028-01
8
Tie Bolt Washer
SS316
36
98002341
8
Nut, Flange, SS, 1/4 - 20
SS18-8
37
98002620
1
Label Cap
LDPE
38
98001418
4
Insert
SS18-8
39
BL017
1
Pump Base
PP
40
98001093
4
Washer
SS18-8
41
98001375
4
Screw
SS18-8
42
98001108
4
Cap, Blue
LDPE
43
1900A0024
2
Main Transfer Tube
PFA
44
98002240
2
O-Ring
1
Viton
45
BL022
1
Shuttle Transfer Tube
PFA
46
98002303
4
O-Ring
1
Viton
47
98003755
1
Screw, Locking Ring
PTFE
48
98003769
2
Screw, Push Plate
PTFE

PAGE 16 MEGA 120D PUMP OPERATION / MAINTENANCE MANUAL
4.6 CLEAN-UP
To help remove potentially dangerous chemicals, the pump can be flushed with DI water
or disassembled and thoroughly cleaned.
4.7 DISASSEMBLY
During the life of the pump it will be necessary to perform certain preventative
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 in performing these procedures.
•Thoroughly clean/flush the pump using DI water (Refer to Section 4.6 Clean-Up).
•Remove tie bolt caps from the slave head.
•Remove nuts from the tie bolts (Slave Head side). Leave tie bolts in place.
•Lay the pump on its side with slave side up.
•Lift off the slave head.
•Remove the main seal and 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 Head Disassembly
•Remove label cap (Slave Head only).
•Remove smart pilot cap from master and slave heads.
•Remove pilot valve and seals from Master and Slave Heads.
•Remove the shuttle cap and seal from the Master Head.
•Remove the shuttle spool assembly from the adapter detent.
•Remove C-ring and detent legs from shuttle spool assembly.
•Remove Detent Adapter
•Do not remove the shuttle sleeve assembly from the shuttle bore.
•Remove the muffler spool and muffler pads from each head.
•Remove quick exhaust ports from heads.
•Remove quick exhaust seals.
•Remove remote exhaust plugs (if necessary).

MEGA 120D PUMP OPERATION / MAINTENANCE MANUAL PAGE 17
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 tool, insert pins in shaft bushing locking ring located in the master head
side of chamber and rotate CCW to remove bushing. Then push out 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 head
touches the pilot piston.
•No light should be visible between the bottom of the button head and the piston.
Figure 4-2
•Slide seal onto pilot valve body until even engagement with the shoulder is reached.
The shoulder is located in the center of the pilot valve body.
•Thread the pilot valve assembly into the pilot bore of the head as shown in Figure
4-3. Tighten to 25 in-lbs. Do not over tighten.

PAGE 18 MEGA 120D PUMP OPERATION / MAINTENANCE MANUAL
Figure 4-3
•Install pilot cap seal.
•Thread pilot valve cap to engage seal. Tighten to 45 in-lbs.
•Repeat process for both heads
•Install label cap (Slave Head only).
4.8.b Shuttle Spool Assembly
•Hold shuttle spool (item 1) upright and 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 the detent ring groove.
See Fig. 3. The completed assembly should look like Fig. 4.

MEGA 120D PUMP OPERATION / MAINTENANCE MANUAL PAGE 19
Figure 4-4
4.8.c Shuttle Assembly (Master Head)
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 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 MEGA 120D PUMP OPERATION / MAINTENANCE MANUAL
4.8.d Quick Exhaust (Both Heads)
•Insert quick exhaust seal.
•Insert quick exhaust port in each head as shown. Tighten to 15 in-lbs. Do not over
tighten.
Figure 4-6
•Install 3 each 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.
•Insert the suction seat. Press firmly using 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 inside the cup shape in the seat.
•Install the check ball. Ensure the o-ring does not become dislodged.
•Install the discharge sleeve. The edge of the non-threaded part of the check bore
should be approximately flush with the top of the discharge sleeve.
•See Figure 4-7 for the proper order of check assembly installation.