Trebor MAGNUM 620D Operation & Maintenance Manual
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Trebor MAGNUM 620D Operation & Maintenance Manual

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Phone: 800-669-1303 or 801-561-0303
Fax: 801-255-2312
e-mail: treborservice@idexcorp.com
MAGNUM 620D PUMP
Operation / Maintenance Manual
SERIAL NUMBER (located on back of product):
PATENTS: U.S. 09642426, U.S. 06106246, U.S. 05971402, U.S. 05370507
4/21/2022 – M620D-E

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Summary of Contents for Trebor MAGNUM 620D

  • Page 1 Phone: 800-669-1303 or 801-561-0303 Fax: 801-255-2312 e-mail: treborservice@idexcorp.com MAGNUM 620D PUMP Operation / Maintenance Manual SERIAL NUMBER (located on back of product): PATENTS: U.S. 09642426, U.S. 06106246, U.S. 05971402, U.S. 05370507 4/21/2022 – M620D-E...

  • Page 2: Table Of Contents

    CLEAN-UP ......................18 DISASSEMBLY ....................19 ASSEMBLY ...................... 27 TESTING ......................36 TROUBLESHOOTING....................37 WARRANTY ....................... 38 CONTACT INFORMATION ..................39 GENERAL CONTACT INFORMATION ............39 TECHNICAL SUPPORT ................... 39 REGIONAL REPRESENTATIVES ..............39 MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL CONTENTS...

  • Page 3: Installation

    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. MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL PAGE 3...
  • Page 4 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 PAGE 4 MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL...

  • Page 5: Options

    A) Flare style tube adapter….1/2”, 3/4", 1” B) PFA tube stub out………...3/4" C) Pillar Super 300…………..3/4”, 1” D) PFA weldable pipe……….3/4" E) NPT adapter nut………….3/4” Figure 2-1 Fluid Port Connection Options MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL PAGE 5...

  • Page 6: Fluid Fittings / Surge Suppressor Hook-Up

    FLUID FITTINGS / SURGE SUPPRESSOR HOOK-UP Surge Suppressor Assembled Height: IN (CM) MODEL SS40 12.63 (32.08) MODEL SS85 14.97 (38.02) Figure 2-2 Fitting/Surge Suppressor Installation NOTE: See Surge Suppressor Operation Manual for detailed installation instructions. PAGE 6 MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL...

  • Page 7: Optional Leak Sensing

    • 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 2-3 Leak Probe Installation MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL PAGE 7...

  • Page 8: Optional Cycle Sensing

    • 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 Cycle Probe Installation PAGE 8 MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL...

  • Page 9: Optional Remote Exhaust

    Torque the remote exhaust plugs (L0209) to 40 IN-LBS. Remove remote exhaust plug (98002243) from each head. • • Install remote exhaust (L0187-01) into the remote exhaust port of each head. Figure 2-5 Remote Exhaust Installation MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL PAGE 9...

  • Page 10: Start-Up

    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 10 MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL...
  • Page 11 Figure 3-1 Flow Performance Curves NOTE: Test information is based on specific conditions and limited sampling. Use for general reference only. MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL PAGE 11...
  • Page 12 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 12 MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL...

  • Page 13: Maintenance

    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.
  • Page 14 MAGNUM 620D Maintenance Schedule Pilot Button C-Ring and Detent Legs Muffler Media Shaft Seal and Shaft Check Balls and O-Rings Diaphragms Check Plug Seal I=Inspect, R=Replace Suction and Discharge Check Cage PAGE 14 MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL...

  • Page 15: Preventive Maintenance Record

    Notes: ________________________________________ ________________________________________ Date: ________ Tech: _____ Notes: ________________________________________ ________________________________________ Date: ________ Tech: _____ Notes: ________________________________________ ________________________________________ Date: ________ Tech: _____ Notes: ________________________________________ ________________________________________ Date: ________ Tech: _____ Notes: ________________________________________ ________________________________________ MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL PAGE 15...

  • Page 16: Recommended Spare Parts

    Check Sleeve Removal Tool T0129 Strap Wrench T0146 3/4” Pin Tool T0147 1” Pin Tool T0148 1/2” Pin Tool T0154 Check Sleeve Insertion Tool T0155 Shaft Bullet T0157 Rebuild Fixture T0144 Cleaning Tool PAGE 16 MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL...

  • Page 17: Parts Illustration

    PARTS ILLUSTRATION Figure 4-1 Exploded View MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL PAGE 17...

  • Page 18: Parts List

    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 18 MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL...

  • Page 19: Disassembly

    Immerse or flush the pump assembly using DI water and a neutralizing agent. • • Remove lever-lock base from bottom of pump. Figure 4-2 • Remove screws (98003207) and quick change base (AW057) from the bottom of the pump. Figure 4-3 MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL PAGE 19...
  • Page 20 Remove tube fittings (98003395) and tubing from the back of the pump. Figure 4-4 Using 1” pin tool (T0147), remove the muffler spools (L0194) and muffler • pads (C0136) from each head. Figure 4-5 PAGE 20 MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL...
  • Page 21 Using the ¾” pin tool (T0146), remove the pilot caps (L0208) and pilot cap seals (W0116) from each head. Figure 4-7 Using the ¾” pin tool (T0146), remove the pilot valves (W0123) and pilot • valve seals (W0117) from each head. Figure 4-8 MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL PAGE 21...
  • Page 22 Using the ¾” pin tool (T0146), remove the shuttle cap (L0104), the shuttle cap seal (L0113) and shuttle (L0131). Figure 4-9 Using the ¾” pin tool (T0146), remove the shuttle cap adapter (L0105). • Figure 4-10 PAGE 22 MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL...
  • Page 23 Wrap the strap wrench around the head (AW099) as shown and with the aid of a ½” drive ratchet wrench, turn the head counter-clockwise to remove. Repeat process for other head (AW098). Figure 4-12 MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL PAGE 23...
  • Page 24 Remove locking screw (98003722) from push plate (AW0741) using a slotted • screwdriver. Using the ¾” pin tool (T0146), remove push plate (AW071) from shaft • assembly. Then remove the shaft assembly from the pump. Figure 4-14 PAGE 24 MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL...
  • Page 25 Using the ¾” pin tool (T0146), remove push plate (AW071) from shaft (AW072). Figure 4-15 Remove shaft seals (98003322) from the shaft bore. • Using the ¾” pin tool (T0146), remove the damper port cap (AW014) and seal • (AW017). Figure 4-16 MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL PAGE 25...
  • Page 26 Figure 4-17 • Gently spray clean with DI water, or rinse by dunking all components in DI water, to remove any trace materials remaining after disassembly. PAGE 26 MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL...

  • Page 27: Assembly

    (AW003). Torque to 60 in-lbs. • Using the ¾” pin tool (T0146), install new damper port seal (AW017) and damper port cap (AW014). Torque to 45 in-lbs. Figure 4-19 MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL PAGE 27...
  • Page 28 Install the thread locking screw with a slotted screwdriver. • Install the shaft bullet (T0155) onto opposite end of shaft. • Figure 4-21 PAGE 28 MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL...
  • Page 29 Continue tightening until the locking screw hole of the plate aligns with the next available hole in the shaft. Install the thread locking screw with a slotted screwdriver. • Figure 4-23 MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL PAGE 29...
  • Page 30 Install mounting fittings (T0156) into pump fluid ports and lock body into • bench mounting fixture (T0136). NOTE: Securely attach mounting fixture (T0136) to work surface using hardware provided. Figure 4-25 PAGE 30 MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL...
  • Page 31 Repeat process for other head (AW098). Figure 4-26 Using the ¾” pin tool (T0146), install shuttle cap adapter (L0105). Torque to • 45 in-lbs. Figure 4-27 MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL PAGE 31...
  • Page 32 See Fig. 3. The completed assembly should look like Fig. 4. Figure 4-28 PAGE 32 MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL...
  • Page 33 Figure 4-30 Using the ¾” pin tool (T0146), install the pilot cap seals (W0116) and pilot • caps (L0208) into each head. Torque the pilot caps (L0208) to 45 in-lbs. Figure 4-31 MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL PAGE 33...
  • Page 34 Figure 4-32 Using the 1” pin tool (T0147), install the muffler pads (C0136) and muffler • spool (L0194) into each head. Torque the muffler spools (L0194) to 40 in-lbs. Figure 4-33 PAGE 34 MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL...
  • Page 35 Install quick change base (AW057) with notched tab facing the front of the • pump and screws (98003207) onto the bottom of the pump body with a slotted screwdriver. Attach quick change base (AW057) to lever lock base • Figure 4-35 MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL PAGE 35...

  • Page 36: Testing

    • Turn off Air Supply and allow the pump to purge for 5 minutes. Dry Suction • 40 psig Supply Pressure Target • Record Suction Value • Target = >8 in-Hg. PAGE 36 MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL...

  • Page 37: Troubleshooting

    Check ball(s) not seating. • Check O-rings for damage; replace if necessary. • Make sure check balls move freely in sleeves. Over pressurization of pump • Reduce discharge pressure by reducing restriction. • discharge. MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL PAGE 37...

  • Page 38: Warranty

    Operation/Maintenance Manual. TREBOR’s obligation under this warranty is limited to repairing or replacing, at TREBOR’s option and at the TREBOR factory, any part or parts thereof which shall, within 1 year after delivery thereof to the original purchaser, be demonstrated to TREBOR’s satisfaction to have been defective.

  • Page 39: Contact Information

    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. TECHNICAL SUPPORT Email: treborservice@idexcorp.com Phone Number: (801) 561-0303 REGIONAL REPRESENTATIVES Web: http://www.treborintl.com/distributors MAGNUM 620D PUMP OPERATION / MAINTENANCE MANUAL PAGE 39...

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