Trebor Mega 255 Manual

10/4/2022 – M255D-A
Phone: [phone] or 801-561-0303
Fax: [phone]
e-mail: [e-mail]
Mega 255 PUMP
Operation / Maintenance Manual

MEGA 255D 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................................................................................9
4MAINTENANCE..........................................................................................................11
4.1 PREVENTIVE MAINTENANCE SCHEDULE...................................................11
4.1.a Preventive Maintenance Record .........................................................13
4.2 RECOMMENDED SPARE PARTS ..................................................................14
4.3 TOOLS..............................................................................................................15
4.4 PARTS ILLUSTRATION...................................................................................15
4.5 PARTS LIST .....................................................................................................16
4.6 CLEAN-UP........................................................................................................17
4.7 DISASSEMBLY ................................................................................................17
4.7.a Head Disassembly...............................................................................17
4.7.b Body Disassembly ...............................................................................18
4.8 ASSEMBLY ......................................................................................................18
4.8.a Pilot Valve (Both Heads) .....................................................................18
4.8.bShuttle Assembly (Master Head).........................................................20
4.8.cQuick Exhaust (Both Heads) ...............................................................20
4.8.dBody Assembly....................................................................................21
4.8.eFinal Assembly ....................................................................................21
4.9 TESTING ..........................................................................................................23
4.9.a Performance Test ................................................................................23
4.9.b Dry Pump.............................................................................................22
4.9.c Dry Suction ..........................................................................................22
5TROUBLESHOOTING ...............................................................................................23
6WARRANTY AND EXCLUSIONS..............................................................................25
7CONTACT INFORMATION ........................................................................................26
7.1 GENERAL CONTACT INFORMATION............................................................26
7.2 TECHNICAL SUPPORT...................................................................................26
7.3 REGIONAL REPRESENTATIVES ...................................................................26

MEGA 255D 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.
**Warning: Due to product weight (82 lb / 37 kg) always use two person lift
when moving Mega 255 Chemical Pump
The following items should be included within the shipping container:
Qty
Item
Description
1
255D
Mega 255D Pump
1
M255D
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 4.4 Parts Illustration) from both
sides of all 8 tie bolts.
2. Apply 100 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 3/8” bolts. It is recommended that the pump be
mounted not more than 15°from level to maintain its self-priming ability and
pumping efficiency.
Air Inlet: 1/2” FNPT (1/2” Dia. [12mm] supply tube minimum).
Air Supply: 25-80 psig (1.4 – 5.5 bar) clean dry air or nitrogen. (For Air
Consumption, See Section 3.2 Performance Charts)
Fluid Ports: Inlet/Outlet Fluid Fittings and Surge Suppressor require torqueing
during pump installation. See Section 2.2 for hook- up diagram
and torque values.
Remote
Exhaust: 3/8” FNPT (Minimum 5/8” Dia. Tube)

PAGE 4 MEGA 255D 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 (5.5 bar)
Maximum fluid temperature: 212°F (100°C)

MEGA 255D PUMP OPERATION / MAINTENANCE MANUAL PAGE 5
2 OPTIONS
2.1 FLUID PORT CONNECTION OPTIONS
NOTE: Use O-ring to seal stainless steel or other rigid plumbing.
Available Options
A) PFA pipe stub out ………..1” and 1 ½”
B) NPT adapter nut ………….1” and 1 ½”
Figure 2-1
2.2 FLUID FITTINGS / SURGE SUPPRESSOR HOOK-UP
Surge Suppressor
Assembled Height: IN (CM)
SS95
17.82 (45.26)
Figure 2-2
NOTE: See Surge Suppressor Operation Manual for detailed installation
instructions.
A)
B)

PAGE 6 MEGA 255D PUMP OPERATION / MAINTENANCE MANUAL
255B16B24 Installation Instructions:
•Install seal (BQ033) in “IN” port
•Assemble BQ035 over BQ036 and install in “IN” port
•Torque nut to 80 in-lb
•Install seal (BQ033) in “OUT” port
•Assemble BQ035 over BQ039 and install in “OUT” port
•Torque nut to 80 in-lb
Figure 2-3
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.)

MEGA 255D PUMP OPERATION / MAINTENANCE MANUAL PAGE 7
•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.
Figure 2-4

PAGE 8 MEGA 255D 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. Increase or decrease setting
to attain desired flow, up to 80 psig (5.5 bar). Minimum is 20 psig.
•Table 1: Consumption / Efficiency can be used to determine approximate air
consumption.
•Refer to Troubleshooting, Section 5, if pump fails to start.
ATTENTION: Prolonged periods of dry running (greater than 5 minutes at a time)
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.

MEGA 255D PUMP OPERATION / MAINTENANCE MANUAL PAGE 9
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
specific gravity and viscosity.
Air Supply
Pressure
(PSIG)
Discharge
Fluid
Pressure
(PSIG)
Air
Used
(SCFM)
Flow
(GPM)
20
0
15.0
44.1
20
10
11.0
28.3
30
0
21.0
54.4
30
20
17.0
32.5
40
0
26.0
58.7
40
20
23.0
38.6
40
30
20.0
45.2
50
0
30.0
62.9
50
20
29.0
45.2
50
40
25.0
27.5
60
0
37.0
65.3
60
20
34.0
48.9
60
40
30.0
34.6
60
50
29.0
27.5
70
0
43.0
68.2
70
20
41.0
51.5
70
40
35.0
37.3
70
60
31.0
23.8
80
0
46.0
68.4
80
20
44.0
52.3
80
40
40.0
38.6
80
60
35.0
26.7
80
70
31.0
19.6
Table 1: Consumption / Efficiency
NOTE: Specification to be used to size regulators and control valves.

PAGE 10 MEGA 255D PUMP OPERATION / MAINTENANCE MANUAL
Figure 3-1: Pressure & Capacity Chart
NOTE: Test information is based on specific conditions and limited sampling.
Use for general reference only.

MEGA 255D PUMP OPERATION / MAINTENANCE MANUAL PAGE 11
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 pump rebuilt by the Trebor factory receives 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 $500.00 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.

PAGE 12 MEGA 255D PUMP OPERATION / MAINTENANCE MANUAL
MEGA 255D Maintenance Schedule
Install
30 Days
3 Months
6 Months
9 Months
12 Months
15 Months
18
Months
21 Months
24 Months
Tie Bolt Torque (100 lb-in)
I
I
I
I
I
Pilot Buttons
I
Shaft Bushing
R
Wear Discs
R
Main Shaft
R
Diaphragms and O-Ring Seals
R
Quick Exhaust Ports and Seals
R
Check Balls and O-Ring Seats
R
Exhaust Mufflers
R
Distribution Pilots
R
Tie Bolts
R
I=Inspect, R=Replace
Note: If suction performance diminishes, inspect the shaft bushing.

MEGA 255D PUMP OPERATION / MAINTENANCE MANUAL PAGE 13
4.1.a Preventive Maintenance Record
Company Name:
_____________________________________________________
Company Address:
_____________________________________________________
_____________________________________________________
Product:
_________________
Serial Number:
________________
Date:
________
Tech:
_____
Notes:
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PAGE 14 MEGA 255D PUMP OPERATION / MAINTENANCE MANUAL
4.2 RECOMMENDED SPARE PARTS
KR255D-00-A Spares Rebuild Kit, which includes:
Part No
Qty
Description
KD255-00-A
1
Diaphragm Kit
Includes:
(2)
(2)
BQ029
98004440
Diaphragm Set
O-Ring
KM255D-00-A
1
Maintenance Kit
Includes:
(2)
(4)
(4)
(4)
98002987
BQ026
98003047
1900B0016
Pilot Button
Muffler Assembly
Quick Exhaust Seal
Quick Exhaust Port
98002303
4
Signal Tube O-Ring, Viton
98004439
4
Transfer Tube O-ring, Viton
98004441
4
O-Ring Seat, PTFE
BQ003
4
Check Ball
BQ008
1
Shaft Bushing
BQ016
4
Wear Disc
BQ022
2
Check Cap Seal
BQ033
2
Fluid Port Seal
BQ052
8
Tie-Bolt Assembly
L0100
16
Tie Bolt Cap
In critical applications, a spare pump is recommended to minimize potential down
time.

MEGA 255D PUMP OPERATION / MAINTENANCE MANUAL PAGE 15
4.3 TOOLS
The following tool kit is recommended as standard service equipment.
KT255-00-0 Mega 255 Tool Kit, which includes:
Part No
Qty
Description
T0228
1
5/16” Allen Key
98002136
2
7/16” Nut Driver
98002859
1
7/16” Socket
98003150
1
Tool Case
98003305
1
Drive Handle
T0226
1
Check Sleeve Insertion Tool
T0227
1
Check Sleeve Removal Tool
T0144
1
Cleaning Tool
T0146
1
¾” Pin Tool
T0147
1
1" Pin Tool
T0148
1
½” Pin Tool
T0225
1
2 3/8” Pin Tool
4.4 PARTS ILLUSTRATION

PAGE 16 MEGA 255D PUMP OPERATION / MAINTENANCE MANUAL
4.5 PARTS LIST
ILL
NO
PART NO
QTY
DESCRIPTION
PM
YEAR #
MATERIAL
1
L0100
16
Tie Bolt Cap
LDPE
2
BQ052
8
Tie Bolt Assembly
2
SS316, PFA
3
BQ001
1
Master Head
PP
4
98004440
2
Main Seal
2
Viton
5
BQ029
2
Diaphragm Set
2
PFA
6
98003769
2
Screw, Push Plate
PTFE
7
BQ009
2
Push Plate
PTFE
8
98003755
1
Screw, Locking Ring
PTFE
9
BQ010
1
Locking Ring
PTFE
10
BQ008
1
Shaft Bushing
2
PTFE
11
BQ007
1
Main Shaft
2
PFA
12
BQ002
1
Body
PTFE
13
L0140
8
Bushing
NPRM, EPDM
14
1900A0028-01
8
Tie Bolt Washer
SS316
15
98002341
8
Tie Bolt Nut
SS316
16
BQ006
1
Slave Head
PP
17
BQ004
2
Discharge Sleeve
PTFE
18
BQ003
4
Check Ball
2
PTFE
19
98004441
4
O-Ring Seat
2
PTFE
20
BQ016
4
Wear Disc
2
PTFE
21
BQ014
2
Suction Sleeve
PTFE
22
BQ005
2
Valve Stop
PTFE
23
BQ022
2
Check Bore Seal
2
PTFE
24
BQ021
2
Check Bore Cap
PTFE
25
BQ019
2
Pump Base
PP
26
98004535
8
Base Bolts
PP
27
98004439
4
Transfer Tube O-ring
2
Viton
28
BQ024
2
Transfer Tube
PP
29
98002303
4
Signal Tube O-ring
2
Viton
30
BQ018
1
Signal Tube
PFA
31
BQ050
1
Shuttle Sleeve Assembly
Ceramic, PTFE
32
L0105
1
Shuttle Adapter
PP
33 BQ044 1 Magnetic Spool Assembly
Ceramic,
PEEK, NiCo
34
L0113
1
Shuttle Cap Seal
PTFE
35
BQ046
1
Magnetic Shuttle Cap
PP, NiCo
36
BQ023
2
Remote Exhaust Plug
PP
37
98003047
4
Quick Exhaust Seal
2
Viton
38
1900B0016
4
Quick Exhaust Port
2
UHMW
39
BQ026
4
Muffler Assembly
2
PP
40
L0167
2
Leak Detection Port Seal
PTFE
41
AM040
2
Leak Detection Port Plug
PP
42
W0117
2
Pilot Valve Seal
PTFE
43 BQ028 2 Pilot Valve 2
PEEK, PTFE,
PPS, Viton
44
W0116
2
Pilot Cap Seal
PTFE
45
BQ015
2
Pilot Cap
PP

MEGA 255D PUMP OPERATION / MAINTENANCE MANUAL PAGE 17
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 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).

PAGE 18 MEGA 255D PUMP OPERATION / MAINTENANCE MANUAL
4.7.b Body Disassembly
•Remove check bore caps using 3/4” pin tool and remove seals.
•Remove sleeves, balls, O-rings and check seat wear rings. 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 4-1
•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 4-2. Tighten to 25 in-lbs. Do not over tighten.

MEGA 255D PUMP OPERATION / MAINTENANCE MANUAL PAGE 19
Figure 4-2
•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).

PAGE 20 MEGA 255D PUMP OPERATION / MAINTENANCE MANUAL
4.8.b 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 shuttle adapter and shuttle sleeve. (Do not
lubricate.)
Figure 4-3
•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.
4.8.c 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 4-4
•Install 2 each muffler pads onto muffler spool and insert into exhaust port.
Tighten to 40in-lbs.