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Summary of Contents for Trebor Mega 255
- Page 1 Phone: 800-669-1303 or 801-561-0303 Fax: 801-255-2312 e-mail: treborservice@idexcorp.com Mega 255 PUMP Operation / Maintenance Manual 10/4/2022 – M255D-A...
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Page 2: Table Of Contents
CONTENTS INSTALLATION ......................3 UNPACKING ...................... 3 TIE BOLT TORQUE ................... 3 UTILITIES / HOOK-UP ..................3 OPTIONS ........................5 FLUID PORT CONNECTION OPTIONS ............5 FLUID FITTINGS / SURGE SUPPRESSOR HOOK-UP ........5 OPTIONAL LEAK SENSING ................6 2.3.a Installation .................... -
Page 3: Installation
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. - Page 4 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.
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Page 5: Options
OPTIONS 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 FLUID FITTINGS / SURGE SUPPRESSOR HOOK-UP Surge Suppressor Assembled Height: IN (CM) SS95... -
Page 6: Optional Leak Sensing
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 •... - 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 MEGA 255D PUMP OPERATION / MAINTENANCE MANUAL PAGE 7...
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Page 8: Start-Up
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 •... -
Page 9: Performance Charts
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 Discharge Flow Pressure Fluid Used Pressure (PSIG) (PSIG) (SCFM) (GPM) 15.0 44.1... - Page 10 Figure 3-1: Pressure & Capacity Chart NOTE: Test information is based on specific conditions and limited sampling. Use for general reference only. PAGE 10 MEGA 255D PUMP OPERATION / MAINTENANCE MANUAL...
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Page 11: 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, a $500.00 evaluation charge will be required. - Page 12 MEGA 255D Maintenance Schedule Tie Bolt Torque (100 lb-in) Pilot Buttons Shaft Bushing Wear Discs Main Shaft Diaphragms and O-Ring Seals Quick Exhaust Ports and Seals Check Balls and O-Ring Seats Exhaust Mufflers Distribution Pilots I=Inspect, R=Replace Tie Bolts Note: If suction performance diminishes, inspect the shaft bushing. PAGE 12 MEGA 255D PUMP OPERATION / MAINTENANCE MANUAL...
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Page 13: Preventive Maintenance Record
4.1.a Preventive Maintenance Record Company Name: _____________________________________________________ Company Address: _____________________________________________________ _____________________________________________________ Product: _________________ Serial Number: ________________ Date: ________ Tech: _____ Notes: ________________________________________ ________________________________________ Date: ________ Tech: _____ Notes: ________________________________________ ________________________________________ Date: ________ Tech: _____ Notes: ________________________________________ ________________________________________ Date: ________ Tech: _____ Notes: ________________________________________... -
Page 14: Recommended Spare Parts
RECOMMENDED SPARE PARTS KR255D-00-A Spares Rebuild Kit, which includes: Part No Description KD255-00-A Diaphragm Kit Includes: BQ029 Diaphragm Set 98004440 O-Ring KM255D-00-A Maintenance Kit Includes: 98002987 Pilot Button BQ026 Muffler Assembly 98003047 Quick Exhaust Seal 1900B0016 Quick Exhaust Port 98002303 Signal Tube O-Ring, Viton 98004439 Transfer Tube O-ring, Viton... -
Page 15: Tools
TOOLS The following tool kit is recommended as standard service equipment. KT255-00-0 Mega 255 Tool Kit, which includes: Part No Description T0228 5/16” Allen Key 98002136 7/16” Nut Driver 98002859 7/16” Socket 98003150 Tool Case 98003305 Drive Handle T0226 Check Sleeve Insertion Tool... -
Page 16: Parts List
PARTS LIST PART NO DESCRIPTION MATERIAL YEAR # L0100 Tie Bolt Cap LDPE BQ052 Tie Bolt Assembly SS316, PFA BQ001 Master Head 98004440 Main Seal Viton BQ029 Diaphragm Set 98003769 Screw, Push Plate PTFE BQ009 Push Plate PTFE 98003755 Screw, Locking Ring PTFE BQ010 Locking Ring... -
Page 17: Clean-Up
CLEAN-UP To help remove potentially dangerous chemicals, the pump can be flushed with DI water or disassembled and thoroughly cleaned. 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. -
Page 18: Body Disassembly
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 •... - 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). MEGA 255D PUMP OPERATION / MAINTENANCE MANUAL PAGE 19...
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Page 20: Shuttle Assembly (Master Head)
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. -
Page 21: Body Assembly
4.8.d 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 Error! Reference source not found..) •... -
Page 22: Final Assembly
• Tighten push plate to 48 oz-in, and then rotate CW until locking screw hole is aligned with the next available notch in shaft. The first push plate can be visually aligned separate from the body. Install push plate locking screw. Tighten to 12 oz-in. •... -
Page 23: Testing
• Lift the slave head and body, while maintaining compression of the main seal, flip the head and body over and insert the tie bolts into the master head. Ensure that the main seal of the master head is not dislodged. Place all bushings &... -
Page 24: Troubleshooting
TROUBLESHOOTING Pump Will Not Start, Fails to Operate Cause: Solution: Insufficient air pressure (must be There must be minimum 20 psig at pump air hook-up. enough to energize the pilot and shuttle valves). Pilot valves ‘buzzing’. Insufficient air volume. See Performance Charts (3.2) for requirements. Reference regulator and control valve capacity specifications. - Page 25 Erratic Cycling Cause: Solution: Leaking detent cap. Tighten and/or replace seal. Supply line restricted (cavitation). Reduce fluid restriction. Check for particles between seal and port. Replace Quick exhaust seal not seating. seal. Pilot valve not following diaphragm Pilot valve piston must slide freely, full travel in pilot correctly.
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Page 26: Warranty And Exclusions
WARRANTY AND EXCLUSIONS See the Trebor Standard Limited Warranty at https://www.treborintl.com/standard-limited-warranty/ PAGE 26 MEGA 255D PUMP OPERATION / MAINTENANCE MANUAL... -
Page 27: Contact Information
Phone Number: (801) 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. TECHNICAL SUPPORT Email: treborservice@idexcorp.com Phone Number: (801) 561-0303 REGIONAL REPRESENTATIVES Web: http://www.treborintl.com/distributors...
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